Project Info
Client:
D2C Apparel
Categories:
Fulfillment, Integrations
Date:
25 February, 2025
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.

