Author: Jason Martin
Reviewed by: Ecommerce Operations Lead
Last updated: October 15, 2025
Executive TLDR
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Holiday demand surges are predictable, but chaos is optional.
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Lock clean data, ASN receiving, and a simple pack matrix before volume hits.
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Centralize inventory in the Midwest and rate shop every label to protect margin.
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Staff to one daily cut off, batch single line orders, and add a second scan at pack.
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Track five numbers daily, on time ship rate, order accuracy, aged inventory, billable weight vs actual, and cost per order.
Want a peak plan that ships fast without burning margin — Talk to an Expert
Table of contents
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Why peak gets messy
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The setup that keeps orders moving
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Inventory and forecasting that actually work
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Pick, pack, and packaging rules that hold under pressure
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Shipping speed without paying air
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The 30 day peak readiness plan
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Why Product Fulfillment Solutions
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FAQ
Why peak gets messy
Peak pressure exposes weak inputs. Bad barcodes, missing dimensions, and fuzzy pack rules slow every station. If cartons arrive with poor labels or wrong counts, the dock jams and inventory is not sellable when you need it. The fix is simple. Clean product data, disciplined receiving, and a pack matrix that removes guesswork.
The setup that keeps orders moving
One product master, one truth
Store the SKU title, barcode, dimensions, weight, case and inner details, and hazard flags in one place. Use one scannable code per sellable unit. Post label placement for unit, inner, carton, and pallet so teams do not improvise. Keep details visible with real time information.
ASN receiving and the dock
Send complete ASNs and print carton labels that match. Book dock times. Aim for 1 to 3 day dock to stock so inventory is sellable before promos hit. If space is tight, expand cleanly with warehousing and storage solutions.
Centralized inventory
A Midwest hub reaches most customers in 1 to 3 days by ground. Keep one inventory pool, then route orders by promise and cost. See 3PL fulfillment and ecommerce fulfillment services.
Inventory and forecasting that actually work
Forecast simply
Use last year’s daily shape, overlay current growth and promo lift, and set a daily units plan. Update every 48 hours with real sell through.
Slot for speed
Place fast movers near pack and separate look alike SKUs. Print large, high contrast bin IDs. Keep promos in their own zone so they do not clog the line.
FEFO for consumables
For supplements, vitamins, and cosmetics, capture lot and expiry at receiving and pick FEFO. Review health and wellness fulfillment services.
Pick, pack, and packaging rules that hold under pressure
Pick rules
Batch single line orders. Cluster pick multi line. Always scan at pick to stop swaps.
Pack matrix
Post which mailer or carton to use by product family. Add inserts only when they help, instructions, care, reorder path. Print shipping labels after the final scan at pack. See pick and pack services.
Quality gate
Add a second scan at pack for look alike SKUs. Keep a small exception lane for rebag or relabel so the main line never stalls.
Shipping speed without paying air
One daily cut off
Staff to clear the queue to zero by cut off. Publish the time and protect it.
Rate shop every label
Blend national and regional carriers and choose the cheapest service that still hits the promise day. Use a simple mailer and box matrix to control DIM. Learn more under discounted shipping rates.
Marketplace readiness
If you feed FBA for fast movers, keep MFN and SFP paths ready for the tail and bundles. For label and data standards, tap EDI solutions and connections and FBA prep services.
The 30 day peak readiness plan
Week 1, clean data and labels
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Product master locked, barcode, dimensions, weights, case and inner.
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Unit, inner, carton, pallet label templates and placement rules posted.
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Pack matrix printed at every bench.
Week 2, inbound discipline
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ASN format locked, dock schedule posted, exception lane defined.
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Target 1 to 3 day dock to stock and report daily.
Week 3, floor and staffing
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Slot fast movers near pack, separate look alikes, print large bin IDs.
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Staff to one daily cut off. Train scan at pick and second scan at pack.
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Dry run the highest volume day of last year.
Week 4, pilot and tune
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Run a three day pilot with promo volume.
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Track order accuracy, on time ship rate, handling time, billable vs actual weight, and cost per order.
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Fix outliers, then lock the playbook.
Why Product Fulfillment Solutions
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Central U.S. hub in Cincinnati with 1 to 3 day ground coverage for most customers.
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Barcode first receiving aligned to your ASN for predictable dock to stock speed.
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Pick and pack standards with right size packaging and scan at pack.
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Small parcel optimization that rate shops every label.
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Retail and marketplace readiness with simple label templates and EDI solutions and connections.
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Kitting and subscription capable for seasonal sets and bundles via kitting assembly services.
FAQ
How early should we start peak prep
Plan four weeks. Clean data and labels in week one, lock ASN and dock in week two, train and slot in week three, pilot in week four.
Do we need multiple warehouses for peak
Start centralized. Add nodes only when data proves savings and service gains.
How do we keep accuracy high under pressure
Scan at pick and add a second scan at pack. Separate look alike SKUs and keep a small exception lane.
Can we hit fast delivery without using air
Yes. A central Midwest hub and rate shopping reach most customers in 1 to 3 days by ground.
What metrics should we watch daily
On time ship rate, order accuracy, aged inventory, billable vs actual weight, and cost per order.