Carton-to-Rack, from 6.4 Days to 1.2
A D2C fashion brand integrated inbound and fulfilment flow, reducing carton-to-rack from 6.4 days to 1.2 and overall order processing time by 81%.
6.4 → 1.2 days
Carton-to-rack turnaround
Integrated inbound + fulfilment
123 → 188
Orders per worker
90 → 59 sec
Pick-to-pack
81% reduction
Order processing
The Situation
Inventory waited in inbound queues before becoming pickable, delaying sellable availability.
Receiving, putaway, and fulfilment operated as disconnected activities with avoidable travel and handoff delay.
Fulfilment speed was measured late in the process while the biggest bottleneck sat upstream.
What We Did
We redesigned receiving, putaway, and fulfilment as one linked operating flow.
- Integrated inbound and fulfilment design into a single process architecture.
- Restructured putaway to make inventory pick-ready faster.
- Optimized picking paths and pick-to-pack methods.
- Removed delays between receiving, storage, and fulfilment steps.
The Results
Carton-to-rack turnaround dropped from 6.4 to 1.2 days.
Orders per worker improved from 123 to 188; pick-to-pack improved from 90 to 59 seconds.
Overall order processing time reduced by 81%, making stock sellable in about a day.
- 01
The real inbound metric is speed to sellable stock.
- 02
If fulfilment feels slow, inspect how long inventory waits before it is pickable.
Industrial Businesses Across 3 Continents