CASE STUDY · SEASONAL FULFILLMENT
More output from the same hours: a seasonal distribution network at peak
The situation
A seasonal retailer runs much of its year through a short, intense peak. The distribution network has to absorb that volume in a narrow window, and labor is the largest cost it controls.
The network was high volume and multi-site, with a WMS rollout underway across locations.
What changed
Flow, slotting, and wave planning. The work started with how product and orders moved through the building. Streamlining flow, slotting, and wave planning raised overall building productivity by 15% and pick rates by 42%, with no increase in labor hours.
Throughput and capacity strategy. Throughput and capacity planning were redefined. The facility set records during peak while reducing second-shift staffing needs.
WMS rollout. Cedric served as the regional WMS subject matter expert, leading rollout strategy and configuration across multi-location fulfillment so the system supported long-term scale.
Leadership pipeline. A leadership development pipeline with assessment systems improved team retention by 10%.
The result
- Pick rates up 42% with no increase in labor hours.
- Overall building productivity up 15%.
- Facility records during peak, with reduced second-shift staffing needs.
- $1.4M year-over-year financial improvement in 2024, with a trajectory to $2M in 2025.
- Team retention up 10%.
Scope: multi-site P&L ownership, leading 4 managers, 23 supervisors, and 500 to 600 associates.
What transfers to your operation
Most buildings have capacity hiding in travel, wave timing, and handoffs. The levers that worked here do not require new equipment: put fast movers where they are cheapest to pick, release work in waves the floor can actually absorb, and plan capacity from the volume curve instead of last year's headcount.
Results achieved in an employment role. They describe past work, not a promise of results for another operation.
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