03/25/2025

Retail Logistics Case Study: DTC Fulfillment Optimization

GEODIS helped a global footwear brand achieve 99.8% order accuracy while processing over 30,000 units per day through automated, direct-to-consumer fulfillment.

Efficient direct-to-consumer (DTC) fulfillment is crucial for retail success. A global footwear brand faced significant challenges managing their vast inventory and meeting consumer expectations for fast, accurate delivery. GEODIS designed and implemented a comprehensive automated solution that dramatically improved their fulfillment capabilities while maintaining exceptional accuracy.

Key takeaways

 

  • Achieved 99.8% order accuracy while managing over 17,000 SKUs in inventory through automated fulfillment systems
  • Scaled operations to handle over 30,000 units per day during peak periods, doubling normal daily throughput of 15,000 units
  • Successfully shipped more than 3 million orders annually using advanced automated packaging solutions
  • Implemented comprehensive returns processing, including refurbishment and re-stocking to maintain inventory integrity

Facts about our footwear client

  • International footwear brand with a global presence
  • Direct-to-consumer business model requiring efficient order fulfillment
  • Large product catalog with over 17,000 SKUs
  • High daily order volumes with significant seasonal fluctuations
  • Focus on customer satisfaction through accurate and timely delivery

 

Challenges for our footwear client

Our client faced several critical operational challenges in their direct-to-consumer fulfillment operations:

 

  • High volume storage requirements: Managing a vast inventory imported from overseas to the United States while requiring optimized storage solutions for on-hand inventory
  • Direct-to-Consumer fulfillment demands: Efficiently processing thousands of orders daily while meeting consumer expectations for increased shipping speed
  • Automation needs: Requirement for advanced automation solutions to boost productivity and accuracy in a high-volume environment
  • Seasonal fluctuations: Ability to scale operations during peak periods without compromising quality or speed

 

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Retail logistics solution and approach

We designed a comprehensive, custom solution that made use of both existing assets and new automated systems to meet our client's storage requirements and fulfillment capacity needs.

Our solution included:

 

  • Multi-level pick module implementation: Zone routing and outbound sortation systems to efficiently store SKUs and fulfill outbound orders
  • Enhanced packaging automation: Introduced on-demand and right-sized packaging automation using CMC machines to reduce shipping costs, increase efficiency, and improve the customer experience
  • Scalable operations design: Created flexible operational processes to handle fluctuations in demand, ensuring fast processing during busy periods—managing 15,000 units per day under normal conditions and scaling to over 30,000 units during peak periods
  • Streamlined returns processing: Developed effective processes for handling returns, including refurbishment, re-boxing, and re-stocking procedures to maintain inventory integrity

 

Footwear client results

Our automated fulfillment solution delivered exceptional results for our client's direct-to-consumer operations:

 

  • 17,000+ SKUs efficiently managed in inventory
  • 30,000+ Units shipped per day during peak periods
  • 99.8% Accuracy rate for order fulfillment
  • >3 million Orders shipped annually with the automated packaging system

 

These results translated into significant improvements in our client's operational efficiency, customer satisfaction, and ability to scale their direct-to-consumer business model. The high accuracy rate ensures customers receive exactly what they ordered, while the scalable throughput capacity allows our client to confidently grow their business without fulfillment constraints.

How GEODIS can help you with  retail logistics

GEODIS is one of the biggest retail logistics providers in the U.S. and around the world. Here's what you can expect when you partner with us for your direct-to-consumer fulfillment needs:

 

  • Advanced automation solutions including multi-level pick modules and right-sized packaging systems
  • Scalable operations designed to handle normal volumes and peak season demands
  • Industry-leading order accuracy rates to enhance customer satisfaction
  • Comprehensive returns management processes to maintain inventory integrity
  • End-to-end visibility throughout your supply chain
  • Expertise in managing complex SKU assortments for fashion and footwear brands
  • Custom-tailored solutions that address your specific business challenges

 

Discover how we can optimize your direct-to-consumer fulfillment operations while ensuring exceptional accuracy and customer satisfaction. Get in touch with GEODIS to explore tailored solutions for your retail logistics needs.

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