Same-day shipping rate jumped from 60% to 94%
A growing e-commerce brand was struggling to keep up with order volume. Pick-pack-ship was manual, error-prone, and couldn't scale past 200 orders per day.
same-day shipping
fewer pick errors
to production
The Challenge
Pick errors were running at 6%, costing $15K/month in reshipping and returns. The team couldn't process more than 200 orders/day without overtime. Peak season was a nightmare.
Our Approach
- 01
Diagnosed: Observed 3 days of warehouse operations and mapped the full order-to-ship workflow.
- 02
Scoped: An intelligent pick routing system with barcode verification and real-time capacity planning.
- 03
Built: Dynamic pick lists optimized for warehouse layout, barcode scanning app, and capacity forecasting.
- 04
Verified: Ran parallel operations for 1 week — new system processed 15% more orders with fewer errors.
- 05
Shipped: Full cutover with 2-day training and a rollback plan for peak season.
The Outcome
Same-day shipping went from 60% to 94%. Pick errors dropped from 6% to 2%. Daily capacity increased to 350+ orders without adding headcount.
“Last Black Friday was the first one where I wasn't panicking. The system just handled it.”
Director of Operations
E-commerce brand, $8M revenue