Description
WooCommerce Plugin
Payload-Logic
Standard delivery plugins assign drivers by order count. Driver A gets 10 orders. Seems fair. Until all 10 orders are cement bags at 50kg each. Driver arrives with a van rated for 800kg. Needs to carry 5,000kg. Vehicle overloaded. Unsafe. Illegal. Dispatch fails. Payload-Logic solves this. Manages delivery capacity by weight and volume, not just order count. Calculates cart weight from products. Checks vehicle limits. Assigns to driver with sufficient capacity. Prevents overload automatically. No more failed dispatches. No more safety violations. Physics-based logistics.
Weight & Volume Limits
Smart Assignment
Capacity Blocking
Fleet Management
The order count fallacy
Hardware store runs local delivery. Uses standard delivery plugin. Sets driver capacity: 10 orders per shift. Driver A assigned 10 orders. Looks balanced. Order 1: Box of screws, 0.5kg. Order 2-10: All cement bags, 50kg each. Total weight: 450.5kg. Driver has scooter rated for 20kg. Arrives to load vehicle. Cannot carry 450kg on 20kg scooter. Physics violation. Order 11 arrives: Single nail, 0.01kg. System says driver at capacity (10/10 orders). Blocks order. Driver sitting with 19kg remaining capacity. Cannot take nail order because hit order count limit. System blind to weight reality. Payload-Logic sees weight. Sees 450kg cement exceeds 20kg scooter. Rejects assignment. Finds truck driver with 3,000kg capacity. Assigns cement there. Scooter driver gets nails. Accurate dispatch. Safe loads. Efficient routing.
Fleet Vehicle Management
Define vehicles: Scooter (20kg max), Sedan (400kg), Van (800kg), Truck (3,000kg). Set weight capacity, volume capacity, max stops. Assign vehicle type to each driver. System knows physical limits. Respects physics during assignment.
Weight & Volume Calculation
Cart contains products. Each product has weight and dimensions in WooCommerce. Payload-Logic sums cart weight automatically. Calculates volume from length × width × height. Converts units (kg/lbs, m³/ft³). Shows total at checkout. Validates before assignment.
Smart Auto-Assignment
Order placed. Payload-Logic checks all active drivers. Filters out vehicles that cannot carry weight/volume. Applies algorithm: Best Fit (most efficient), First Fit (fastest), or Round Robin (even). Assigns to optimal driver. Updates vehicle current load. Prevents overload automatically.
Capacity Blocking
All vehicles at weight limit. Customer tries to order 200kg cement. Payload-Logic checks capacity. Zero vehicles can carry 200kg. Blocks local delivery option at checkout. Shows message: “Delivery unavailable due to capacity.” Prevents impossible orders. Protects operations.
Why order count fails logistics
Garden center sells mulch and flowers. Uses standard delivery plugin. Sets capacity: 15 orders per driver. Driver B assigned 15 orders. Seems balanced. Orders 1-5: Flowers, 2kg each (10kg total). Orders 6-15: Mulch bags, 40kg each (400kg total). Total weight: 410kg. Driver has sedan rated for 400kg. Arrives at warehouse. Can fit flowers fine (10kg). Tries to load mulch (400kg). Sedan suspension sags. Unsafe. Over weight limit by 10kg. Dispatch coordinator realizes problem. Must split orders. Calls second driver. Extra fuel cost. Customer delivery delayed. All because system counted orders, not weight. If order 16 arrives (single flower pot, 2kg), system blocks it. Driver at 15/15 order limit. Vehicle has 0kg currently loaded (flowers delivered, mulch split to other driver). Sitting with 400kg empty capacity. Cannot take 2kg flower pot. Order count says no. Physics says yes. System broken. Payload-Logic fixes this. Sees 410kg order. Sees 400kg sedan. Rejects assignment. Finds truck driver (3,000kg capacity, 200kg current load). Assigns all mulch there. Sedan driver keeps flowers (10kg under 400kg limit). Perfect fit. Safe loads. Efficient routing.
Order count ignores physical weight and volume reality
Hardware store: Order 1 = box of screws (0.5kg). Order 2 = cement bag (50kg). System treats both as “1 order.” Driver assigned 10 orders: 1 screw box + 9 cement bags = 451kg. Scooter rated 20kg. Driver cannot carry 451kg on 20kg scooter. Dispatch fails. Operations chaos. Standard plugins blind to weight. Only see “10 orders = full capacity.” Physics disagrees.
Blocks light orders when driver at order limit but under weight limit
Driver A: 10/10 orders assigned. Current load: 15kg (delivered 9 orders, 1 remaining flower pot at 15kg). Vehicle capacity: 400kg sedan. Available capacity: 385kg remaining. Order 11 arrives: Single nail, 0.01kg. System blocks order. Driver at order count limit. Reality: driver has 385kg empty capacity. Could carry 19,250 more nails. System says no because order count maxed. Weight capacity ignored. Efficiency lost.
Payload-Logic: Assigns by weight and volume, respects vehicle physics
Order placed: 450kg cement. Payload-Logic calculates weight. Checks all drivers. Scooter A: 20kg max, 5kg loaded = 15kg available. Rejected (450kg exceeds 15kg). Van B: 800kg max, 600kg loaded = 200kg available. Rejected (450kg exceeds 200kg). Truck C: 3,000kg max, 500kg loaded = 2,500kg available. Accepted (450kg fits in 2,500kg). Assigns to Truck C. Updates load: 500kg + 450kg = 950kg current. Safe assignment. No overload. Physics respected. Dispatch succeeds.
🛠️ Real Example: Hardware Store Dispatch Failure
Before: Order count logic causes vehicle overload
Monday morning. 15 orders come in. Driver A has sedan (400kg max). Standard plugin assigns first 10 orders to Driver A (seems fair, 10/10 capacity). Orders breakdown: 2 paint cans (5kg each = 10kg), 8 cement bags (50kg each = 400kg). Total: 410kg. Driver A loads sedan. Suspension sags. Over limit by 10kg. Unsafe. Illegal. Cannot drive. Dispatcher realizes problem at 9 AM. Must call Driver B (truck, but scheduled for afternoon). Driver B comes early. Takes cement bags. Driver A delivers paint only. Customer cement delivery delayed 4 hours. Extra fuel cost for unscheduled Driver B trip. Customer complaint. All because system assigned by order count, not weight.
After: Weight-based logic prevents overload automatically
Same Monday. Same 15 orders. Payload-Logic installed. Orders come in. System calculates weight per order. Paint: 5kg each. Cement: 50kg each. Driver A sedan: 400kg max capacity. Auto-assignment runs. Assigns 2 paint orders to Driver A (10kg total, well under 400kg). Evaluates cement order 1 (50kg). Checks Driver A: 10kg + 50kg = 60kg. Fits. Assigns. Cement order 2: 60kg + 50kg = 110kg. Fits. Continues. Cement order 8: 360kg + 50kg = 410kg. Exceeds 400kg max. Rejects Driver A. Finds Driver B (truck, 3,000kg max, 0kg current). Assigns remaining cement to Driver B. Final: Driver A has 7 orders (360kg, safe). Driver B has 8 orders (400kg, safe). Zero overload. Zero dispatch chaos. Zero customer delays. Physics respected. Operations smooth.
🌱 Garden Center Volume Constraint Example
Challenge: Garden center delivers soil (heavy) and plants (bulky but light). Soil: 40kg per bag, small volume. Plant: 2kg, huge volume (1m³ nursery pot). Standard plugin assigns by order count. Misses volume constraint.
Solution: Payload-Logic tracks both weight AND volume. Van specs: 800kg max weight, 3m³ max volume. Order A: 10 soil bags (400kg, 0.5m³). Order B: 8 plants (16kg, 8m³). System checks both constraints. Order A to van: 400kg weight (fits), 0.5m³ volume (fits). Order B to van: 16kg weight (fits), 8m³ volume (exceeds 3m³ max). Rejects. Finds box truck (5,000kg, 15m³). Assigns plants there. Optimal.
Result: Soil goes in van (weight-optimized). Plants go in truck (volume-optimized). No cramming plants into sedan. No failing to load due to volume. Dual-constraint logic handles real-world complexity. Standard plugins only check weight OR only check order count. Miss half the picture.
Complete feature set
Full fleet capacity management system. Weight and volume tracking. Smart auto-assignment. Capacity blocking. Driver management. Order tracking. Physics-based logistics.
🚚 Fleet Management
• Add vehicles (Scooter to Semi)
• Set max weight capacity
• Set max volume capacity
• Set max stops per shift
• Define vehicle types
• Active/inactive status
• Unit conversion (kg/lbs, m³/ft³)
• Unlimited vehicles
⚖️ Weight & Volume
• Auto-calculate cart weight
• Auto-calculate cart volume
• Sum from product data
• Unit conversion automatic
• Display at checkout
• Validate before assignment
• Dual-constraint checking
• Real-time calculation
🎯 Auto-Assignment
• Best Fit algorithm (efficient)
• First Fit algorithm (fast)
• Round Robin (even distribution)
• Filter by capacity available
• Automatic on order complete
• Manual override available
• Order weight/volume tracking
• Assignment history logging
👤 Driver Management
• Enable users as drivers
• Assign default vehicles
• Track current load per driver
• Driver shift scheduling
• Vehicle assignment per shift
• Driver capacity monitoring
• Driver order history
• Unlimited drivers
🚫 Capacity Blocking
• Check capacity at checkout
• Block local delivery if full
• Show capacity warnings
• Configurable buffer (safety margin)
• Real-time capacity calculation
• Prevent impossible orders
• Customer-friendly messages
• Protect operations automatically
📊 Order Tracking
• View assigned driver per order
• View order weight/volume
• See vehicle assigned
• Assignment meta box in admin
• Order notes with details
• Manual reassignment option
• Assignment history
• HPOS compatible tracking
Perfect for
Hardware Stores
Screws (light) and cement bags (heavy) in same catalog. Variable weight per order. Scooters for small orders, trucks for bulk. Payload-Logic assigns correctly. Prevents scooter from carrying cement. Prevents truck waste on screw orders.
Garden Centers
Soil bags (heavy, compact) and potted plants (light, bulky). Weight AND volume constraints. Sedans for soil. Box trucks for plants. Dual-constraint checking ensures correct vehicle type per order type. No cramming trees into sedans.
Wholesale Distributors
B2B bulk orders. 500kg pallets. 2,000kg shipments. Local fleet delivery. Sedans cannot carry pallets. Vans limited to 800kg. Semi-trucks handle 20,000kg. Payload-Logic matches order size to vehicle class automatically. Efficient fleet utilization.
Grocery & Meal Kit Delivery
Variable order sizes. Single meal for 1 person (2kg). Weekly stockpile for family of 5 (40kg). Bikes for singles. Vans for families. Weight-based assignment optimizes fuel costs. Right vehicle for right order size.
Common use cases
Use Case 1: Mixed Product Order
Order contains 5 paint cans (25kg) and 10 cement bags (500kg). Total: 525kg. Payload-Logic checks Driver A sedan (400kg max). Rejects (525kg exceeds 400kg). Checks Driver B truck (3,000kg max, 200kg loaded). Accepts (525kg + 200kg = 725kg, under 3,000kg). Assigns to truck. Safe dispatch.
Use Case 2: Capacity Buffer Safety Margin
Van rated 800kg max. Settings: 10% capacity buffer. Effective max: 720kg (800kg × 0.9). Order: 750kg. Without buffer: would assign (750kg < 800kg). With buffer: rejects (750kg > 720kg). Finds truck instead. Buffer prevents edge-case overloads from weight estimation errors or packaging.
Use Case 3: Volume Constraint Scenario
Furniture order: 8 chairs (5kg each, 0.5m³ each). Total: 40kg weight, 4m³ volume. Sedan specs: 400kg weight (fits), 1m³ volume (does not fit). Weight check passes. Volume check fails. Rejects sedan. Finds van (800kg, 5m³). Assigns there. Both constraints satisfied.
Use Case 4: Over-Capacity Blocking
All drivers at capacity. Customer adds 200kg order to cart. Proceeds to checkout. Payload-Logic checks: zero vehicles can carry 200kg. Blocks local delivery shipping method. Shows message: “Local delivery unavailable.” Customer must choose different delivery date or pickup. Prevents accepting impossible orders.
🚀 Setup Process
Step 1: Install Payload-Logic and WooCommerce (both required)
Step 2: Payload-Logic → Vehicles → Add vehicles (name, type, weight max, volume max)
Step 3: Users → Edit user → Enable delivery driver → Assign default vehicle
Step 4: Payload-Logic → Settings → Configure auto-assignment algorithm and capacity rules
Step 5: Products need weight/dimensions set. Orders auto-calculate. Drivers auto-assigned. System operational.
Frequently asked questions
What if products do not have weight set?
System calculates weight as 0kg for products without weight data. For best results, set product weights in WooCommerce. Bulk edit available in Products → All Products → Bulk Edit. Weight data essential for accurate capacity management.
Can I disable auto-assignment and assign manually?
Yes. Settings → Auto-Assignment → Disable. Then manually assign from order edit screen. Order meta box shows available drivers with capacity. Select driver, click assign. Manual override always available even with auto-assignment enabled.
What assignment algorithms are available?
Best Fit: Assigns to vehicle with least remaining capacity after order (most efficient, prevents wasting large vehicle on small order). First Fit: Assigns to first available driver (fastest). Round Robin: Distributes evenly across drivers (balanced workload). Configure in Settings.
Does this work with my theme?
Yes. All frontend styles inherit from active theme. Zero styling conflicts. Backend admin uses WordPress admin styles. Compatible with any WooCommerce-compatible theme.
What happens when all vehicles are at capacity?
If capacity blocking enabled: local delivery shipping method hidden at checkout. Customer sees message “delivery unavailable.” Must choose different date or pickup. Prevents accepting orders that cannot be fulfilled. Protects operations from over-commitment.
Can I track volume as well as weight?
Yes. Volume calculated from product dimensions (length × width × height). Set dimensions in product data. System calculates cubic meters or cubic feet. Checks both weight AND volume constraints. Prevents assigning bulky orders to small vehicles even if weight fits.
What is capacity buffer and why use it?
Safety margin percentage (default 10%). Vehicle 800kg max, buffer 10%, effective max 720kg. Prevents edge-case overloads from packaging weight, weight estimation errors, or unexpected items. Recommended: 10% for standard operations, 15-20% for variable-weight products.
What about updates and support?
One-time purchase includes lifetime updates. Future WordPress compatibility free. Future WooCommerce compatibility free. No renewal fees. Pay once, own forever.
Technical requirements
WordPress
6.0 or higher
WooCommerce
8.0 or higher
PHP
8.2 or higher
Compatibility
HPOS & All themes
