Embedding-based retrieval (EBR) is foundational to large-scale e-commerce search, yet its effectiveness is often constrained by the quality of training signals and the representational capacity of the encoder. Standard dual-encoders suffer from a training-inference gap: they are optimized on narrow candidate pools but must discriminate against hundreds of millions of items during inference. Furthermore, while transitioning to higher-capacity backbones can mitigate this gap, simply replacing a mature model can lead to inconsistent retrieval behavior and a loss of the domain-specific knowledge established in previous iterations. In this paper, we present a unified pipeline deployed at Walmart that addresses both signal quality and model evolution. Our contributions are two-fold: (1) Hybrid Hard Negative Mining: We integrate Online Cross-Batch Sampling to increase negative diversity by an order of magnitude and Hybrid Offline Mining, which combines cross-encoder predictions with metadata heuristics to identify nuanced mismatches. (2) Legacy-Aware Distillation: We transition from DistilBERT to a higher-capacity GTE-base encoder. To ensure a smooth and superior transition, we introduce a Warm-Start Distillation technique that transfers domain-specific expertise from the legacy model to the new backbone. Validated through extensive offline experiments and online A/B testing, the proposed pipeline is deployed in live production, delivering a +7.34% improvement in NDCG@5 and a +0.50% lift in gross revenue.

In embedding-based retrieval, Approximate Nearest Neighbor (ANN) search enables efficient retrieval of similar items from large-scale datasets. While maximizing recall of relevant items is usually the goal of retrieval systems, a low precision may lead to a poor search experience. Unlike lexical retrieval, which inherently limits the size of the retrieved set through keyword matching, dense retrieval via ANN search has no natural cutoff. Moreover, the cosine similarity scores of embedding vectors are often optimized via contrastive or ranking losses, which make them difficult to interpret. Consequently, relying on top-K or cosine-similarity cutoff is often insufficient to filter out irrelevant results effectively. This issue is prominent in product search, where the number of relevant products is often small. This paper introduces a novel relevance filtering component (called "Cosine Adapter") for embedding-based retrieval to address this challenge. Our approach maps raw cosine similarity scores to interpretable scores using a query-dependent mapping function. We then apply a global threshold on the mapped scores to filter out irrelevant results. We are able to significantly increase the precision of the retrieved set, at the expense of a small loss of recall. The effectiveness of our approach is demonstrated through experiments on both public MS MARCO dataset and internal Walmart product search data. Furthermore, online A/B testing on the Walmart site validates the practical value of our approach in real-world e-commerce settings.