SUCCESS STORIES
A well-known consumer wellness brand manufactures and distributes microwavable, heatable plush products and wellness items infused with French lavender, providing aromatherapy and comfort to customers nationwide. Founded in 1995, the company offers a broad product portfolio including plush animals, slippers, neck wraps, and eye masks filled with natural grains for warmth and calming weight. Operating from the Midwest, the organization supports a growing multi-channel business model spanning direct-to-consumer (DTC), business-to-business (B2B), and marketplace fulfillment. The distribution center ships more than 2 million lines annually and experiences significant seasonality, with demand increasing 40–50% during the holiday peak between Thanksgiving and New
Rapid growth and peak-season demand placed significant strain on warehouse execution, inventory accuracy, and multi-channel fulfillment performance. Misalignment between the Deposco WMS and Sage ERP created inconsistencies in inventory allocation across B2B, DTC, and Amazon channels, leading to split shipments, false backorders, and uncertainty around available-to-promise inventory. Peak periods amplified these issues, increasing late shipments and operational stress, while upcoming manufacturing startup plans introduced new space requirements for WIP, QA, and staging—further complicating workflow and increasing administrative burden from weekly WMS–ERP reconciliations.
Alpine conducted a focused best-practice assessment to quickly identify root causes and stabilize operations, combining physical workflow analysis with a detailed review of the WMS–ERP interface. The team aligned Sage and Deposco to a consistent operational “truth” for inventory, correcting allocation logic and reducing system-driven errors. Improvements were also made to wave planning controls and replenishment visibility to strengthen peak execution, while facility reorganization efforts reclaimed space, improved zoning, reduced cross-traffic, and relocated value-added activities to better support manufacturing readiness.
The engagement delivered immediate operational stabilization and a clear roadmap for sustainable growth. Inventory logic alignment reduced split shipments and eliminated false backorders, improving fulfillment reliability across channels. Enhanced wave control and replenishment reporting strengthened peak prioritization and reduced reactive floor management, while space recovery initiatives decreased congestion and prepared the facility for WIP, QA, and staging expansion. With additional executive-level recommendations around cycle counting, labor governance, and shipping redesign, the company gained a practical, prioritized path to improve inventory visibility, stabilize peak performance, and support the next phase of operational complexity.
