Automated USPS Tracking Resolution with Custom AI Workflows

About Client

  • A leading technology-first automation provider based in the States, working in advanced workflow solutions for businesses across North America and Europe.
  • With 200+ interactive projects in 15+ countries, they mix art and engineering to create digital experiences for global brands and cultural institutions.

Problem STATEMENT

The client’s support team was buried with a constant stream of USPS tracking inquiries, many of which were either incomplete, invalid, or poorly formatted. As the volume grew, manual processing became increasingly unsustainable.

Missing Tracking Number Validation

Without any automated checks in place, agents had to manually validate tracking numbers, creating bottlenecks and slowing down response times.

Manual Email Handling with No Prioritization

Emails were processed one by one, with no workflow segregation or intelligent labeling, making it hard to differentiate between valid, invalid, or high-priority queries.

One-Size-Fits-All Responses

The support team lacked a system to tailor responses based on the nature of each query, leading to inconsistent user experiences and redundant manual effort.

Heavy Reliance on Support Staff

From drafting replies to applying Gmail labels, nearly every part of the workflow required human intervention, taking valuable time away from more strategic tasks.

No Safety Nets or Backup Flows

There were no fallback mechanisms for scenarios like invalid inputs or USPS service disruptions, increasing the risk of dropped queries or broken user journeys.

Solution

To ease the burden on the internal support, developers at DataToBiz designed a smart, logic-first automation pipeline. It reads incoming emails, validates tracking numbers, interacts with USPS, and responds accordingly, all with minimal human intervention.

Intelligent Tracking Number Validation

The system automatically scans incoming emails for tracking numbers using regex and length filters (20–22 digits). Any invalid or missing entries are flagged right away, no manual lookup needed.

USPS Site Automation via Playwright

Using Playwright, the pipeline simulates a user on the USPS website, retrieving real-time tracking statuses. It’s built to handle dynamic page elements and respond smoothly even under slow-loading conditions.

Smart Gmail Workflow Segregation

Emails are automatically sorted and labeled as “Done” (successfully processed) or “Human Review” (needs manual attention), streamlining the entire support workflow.

Auto-Generated Reply Drafts

Based on the result: valid, invalid, or empty tracking, personalized replies are drafted in Gmail, ensuring customers always receive a response, even when data is missing.

Resilient Folder & Resource Handling

The system creates necessary directories for logs and screenshots on the fly, reducing the chance of runtime errors and broken executions.

Built-In Fail-Safes

From USPS downtime to malformed tracking numbers, all edge cases are gracefully managed with clear logs, error flags, and safe shutdowns, keeping operations steady even when things go off-script.

Technical Implementation

USPS Interaction Layer

  • Automated USPS tracking page navigation using Playwright

  • Retry logic handles temporary web failures

  • Dynamically selects the correct “Search” button despite DOM changes

Input Validation Layer

  • Validates tracking numbers using regex (20–22 digits)

  • Fallback logic extracts probable tracking numbers from the email body

Email Handling & Labeling

  • Gmail API scans unread emails for tracking requests

  • Label emails as “Done” or “Human Review” based on the outcome

  • Drafts customized reply emails based on validation status

Directory & Logging

  • Auto-creates necessary folders (e.g., /tracking_numbers/)

  • Logs each step with detailed debug messages

  • Captures screenshots for failure points

Workflow Orchestration

  • Linear, exception-safe flow at every stage

  • Ensures browser shutdown across all paths to prevent memory leaks

Technical Architecture

Automated USPS Tracking Resolution

Business Impact

Smarter Email Workflows from Day One

Manual handling for tracking queries was reduced by 50%, as routine emails were auto-triaged and resolved without human intervention.

End-to-End Automation That Sticks

The system achieved 100% automation in labeling and reply drafting, freeing up the support team from repetitive inbox management.

Built for Breakpoints, Ready for Scale

Thanks to its fail-safe design, the workflow ran with zero downtime, even when USPS made front-end changes or emails had malformed input.

Visibility that Accelerates Debugging

With step-level logs and visual snapshots, root cause analysis became 70% faster, minimizing the time spent on troubleshooting issues.

In this foundational phase, our experts delivered an automation engine that transformed email-based USPS tracking support. By managing edge cases and delivering timely responses, the system itself replaced bottlenecks with scalable and hands-off efficiency.

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