Case Studies
Damage Reduction for DTC Shipping
A direct-to-consumer program reduced transit damage by redesigning pack fit, cushioning strategy, and fulfillment handling rules.
Overview
A direct-to-consumer program reduced transit damage by redesigning pack fit, cushioning strategy, and fulfillment handling rules.
Data-Backed Diagnosis
Mapped failure patterns by route and handling stage before redesign.
Targeted Redesign
Focused on movement control, cushioning zones, and secondary packaging geometry.
Measured Rollout
Used phased rollout with route-level monitoring to verify improvements.
Initial Challenge
Return rates increased during campaign periods, with significant product damage during long-distance mixed-carrier routes.
Execution Approach
The redesign prioritized internal fit control and route-matched cushioning profiles, then validated performance with targeted transit testing.
Outcome
Damage claims and replacement workload dropped materially, while fulfillment operations kept packing speed targets.