Resolving Fulfillment Constraints at Scale

CLIENT: Scaling E-Commerce, 30-person team

DETAILS ANONYMIZED AT THE CLIENT'S REQUEST.

THE DIAGNOSIS

The company hit $8M in revenue but the fulfillment process was entirely manual. Orders were tracked across three different spreadsheets, customer service was flooded with 'Where is my order?' tickets, and the warehouse team was working 14-hour days just to keep up. The CEO was spending 4 hours a day manually routing exception orders.

EXECUTION & OUTCOME

When growth outpaces infrastructure, the result is compounding constraints. This e-commerce brand had built an incredible marketing engine, but their operational backend was a liability. Every new order increased the strain on a manual, brittle system. We parachuted in to map the entire fulfillment lifecycle. The core issue wasn't the warehouse team, it was the lack of a single source of truth. We designed a custom Airtable architecture to serve as the operational hub, integrated directly with Shopify and their 3PL via Make.com. Exception routing, previously handled manually by the CEO, was codified into logic rules and automated. The result was a scalable machine. The company tripled their order volume in Q4 without adding a single operations headcount, and the CEO was finally able to step away from the warehouse floor and return to building the business.

Deployed Architecture

  • Custom Airtable WMS (Warehouse Management System)
  • Make.com automated order routing from Shopify to WMS
  • Automated Zendesk ticket resolution for shipping status
  • Executive dashboard for real-time fulfillment metrics

Measurable Impact

4 Hires
Headcount Avoided
20hrs/wk
CEO Time Reclaimed
-85%
Order Error Rate

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CLIENT: Professional Services Firm, 45-person team

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