L O A D I N G

GearUp

GearUp/

Project Info

Client: D2C Apparel
Categories:
Fulfillment, Integrations
Date: 25 February, 2025
Featured Cases
NovaWear
NovaWear
D2C Apparel
HomeGlow
HomeGlow
Home Goods Retailer

Overview

NovaWear is a fast-growing direct-to-consumer apparel brand known for limited drops and seasonal collections. Before Apexus, they were fulfilling in-house from a single coastal warehouse, struggling with promo spikes, 2-day coverage gaps, and rising shipping costs. Apexus designed a multi-node fulfillment program, standardized pick/pack quality, and introduced real-time visibility—turning launch days from “all hands” crises into routine operations.

Industry: D2C Apparel · Regions Served: US + Canada (expansion ready for UK/EU)

Engagement Length: 9 months (ongoing) · Annual Order Volume: 250k+
Primary Goals: Faster delivery, lower cost per order, and error reduction during drops

Challenges

Delivery Speed & Coverage: Single node created 4–6 day lanes for key inland markets; 2-day promise inconsistent.
Launch-Day Volatility: Flash sales and influencer collabs produced 10–15× order spikes; manual batching collapsed under load.
Rising CPO: Dimensional weight and suboptimal carrier mix increased cost per order.
Quality Drift: Pick/pack errors during peaks and inconsistent branded insert logic.

Results (First 90 Days)

37% faster average delivery time (2-day became the norm for core markets).
98.9% on-time fulfillment rate, including promo spikes.
18% lower cost per order via carrier mix + DIM right-sizing.
<0.5% error rate with scan-to-pack and QA at handoff.
Return processing <24h, improving exchange/repurchase velocity.