FFI works closely with a contract assembler for the U.S. Army. This contractor provided multiple components that needed to be assembled with guaranteed accuracy for use in the field. Only some of these components were required, depending on the equipment used. FFI was asked to assemble these kits and package items to avoid breakage or deterioration during shipment and storage. Correct packaging was critical since material needed to last for long periods in harsh climates. FFI uses the kitting module within its fulfillment system to manage the task. The company’s systems specialists wrote a program to ensure that kit contents were accurate. Each of the kit components has a bar code. The system does not close out the kit until each item is individually scanned. The program is now in its second year of delivering 100% order accuracy. In the case of problems, FFI can track items back to the exact kit in which they were shipped.
category: Featured Case Study
The Ethical Manufacturing Order Fulfillment Success Story
The shoppers of today expect their items to arrive on their doorstep quickly. They want the ability to track their items during every step of their journey, and they expect their items to arrive in pristine condition. These buyer expectations were becoming a challenge to one of our customers, an ethical manufacturing customer. A wholesale B2B and B2C retailer, they sell products to wholesale boutique shops, large retailers, and Amazon direct, that were created by artisans and artists. They were growing rapidly and needed to optimize their e-commerce order fulfillment processes.
Growing Businesses Need the Right Fulfillment Partner
This manufacturing customer’s accelerating product demand was creating a fulfillment bottleneck. Having their orders kitted, picked, packed, and fulfilled out of their increasingly cluttered basement was no longer an option. They needed a fulfillment solution that could scale and support the growth of their business, and they turned to FFI to help them.
Within their first full year of operation after switching to Fulco Fulfillment Inc.’s services, our ethical manufacturing customer was able to triple their order volume.
The Customer Had Unique Fulfillment Challenges
Shipping: Finding a provider that has the correct expertise to keep up with order volumes.
Location: Pinpointing location and finding a 3PL partner located in the NY/NJ tri-state area to give the customer the ability to quickly and conveniently access their product.
Specialized Packaging: Finding a fulfillment provider with excellent attention to detail who supports their personalized touch. All packages are paper-wrapped and sealed with a logo sticker, including packing tape customized with their colorful logo.
Sales and Marketing: Getting meaningful, trustworthy fulfillment services so that they could focus on sales and marketing and continue to grow their business.
Trade Shows: Our ethical manufacturing customer displays at major trade shows and holiday markets throughout the year. In this method of marketing, the product has a chance to shine and captivate new customers. The fulfillment provider must get the product there on time and in good condition.
Customer Communication: Customers expect excellent communication, including phone calls, frequent status updates, and shared details about deliveries.
Timing Is Everything: At the time, peak shopping season was just around the corner and this ethical manufacturing company needed a solution that could help them meet and exceed their demands even when facing an unknown future.
Successful Fulfillment Creates Business Growth
Shipping/Freight Savings: Outsourcing fulfillment to FFI has allowed this customer to enjoy the combined freight discount offered by FFI, substantially lowering their shipping costs.
Inventory Management: Using Fulco Fulfillment Inc.’s Order Management System (OMS) and Warehouse Management System (WMS), this ethical manufacturing customer saw their inventory management streamlined. With the Veracore software platform, they manage inbound and outbound shipments along with inventory volumes and order status in real time.
Determining the Right Location: The customer’s base of operations in the New York East Coast Area meant that FFI in Dover, NJ was in an ideal location, conveniently located right off of Route 80, Route 46, and with access to Route 287 and Route 10. Clients can visit the warehouse and stop in for a continued hands-on type of approach.
Dedicated Client Service Manager: At FFI, a dedicated client service manager is assigned to each account and operates under the client service manager team of dedicated pickers. Our team ensures quality control of customized packaging by learning and mastering the details of each client’s specialized packaging needs.
Focus on What They Do Best: By choosing FFI to handle their fulfillment needs, our ethical manufacturing customer was able to increase marketing efforts and sales instead of being consumed by managing shipping and inventory.
Holiday Markets and Trade Show Solutions: FFI’s order management system allowed our client to allocate, manage, and track all of their tradeshow assets. They received special deliveries of materials directly to the New York City holiday show in a small delivery window and, upon conclusion of the show, items were picked up by FFI personnel and received back into client inventory.
24/7 Web Access: Our ethical manufacturing client now has 24/7 web access to its entire inventory via our web portal. They can generate reports, set understock notification levels, access order inquiries to track shipping status, or see a history of inventory usage.
Consistent Results: The FFI team has tested and optimized processes that streamline operations and get orders out on time. Even during peak season, our team has kept and maintained an astounding 99.8% accuracy on all orders.
Fulco Fulfillment Provides the Right 3PL Solutions
Fulco Fulfillment Inc. has improved this ethical manufacturing customer’s supply chain. It reduced the amount of time it takes orders to reach their valuable customers and increased the efficiency of their orders from vendors. In addition, FFI provided logistics solutions at a variable cost to maximize efficiency during the retailer’s peak and non-peak seasons.
We can have the same powerful effect on your business! To learn the ways we can solve your specific challenges, give us a call at 973-361-1700 or fill out our contact form.
How FFI Scaled Fulfillment Operations Without Adding Complexity
Growth is not always measured by higher-order volumes or a larger product catalog; it can also take the form of operational transformation. When one Canada-based powersports parts company implemented a new ERP system, the goal was to gain greater visibility into inventory and create more detailed tracking across its supply chain. While the company’s products and overall inventory levels remained relatively consistent, the new system required inventory to be managed differently within the warehouse. To support the transition, Fulco Fulfillment Inc. (FFI) partnered with the client to redesign warehouse processes, optimize inventory placement, and create a fulfillment operation capable of enhanced inventory visibility and control.
The Challenge: Adapting Warehouse Operations to Meet New ERP Requirements
Prior to the ERP implementation, products were often managed under a single inventory identifier, regardless of fulfillment method. The new system introduced more granular inventory controls, allowing the customer to segment inventory by channel, fulfillment requirements, and shipping methods. Although the number of products did not increase, the warehouse operation needed to evolve to support the new structure and reporting standards. The challenge was clear: enable greater inventory visibility and operational precision without sacrificing fulfillment speed or efficiency.
Building a Scalable, Data-Driven Warehouse Operation
To prepare for the ERP transition, FFI evaluated inventory data, warehouse workflows, and long-term growth requirements to create a more scalable fulfillment environment. Additional shelving was installed in a dedicated warehouse zone, allowing inventory to be organized more effectively to align with ERP-driven inventory segmentation. Rather than simply creating more storage space, FFI optimized the layout based on real product movement, velocity, and usage patterns. Using historical inventory data and usage analytics, FFI identified high-velocity SKUs and positioned them accordingly. High-velocity items were placed near packing and shipping stations to reduce travel time and improve picking efficiency. Lower-velocity inventory was stored farther from the packing area, maximizing warehouse space while maintaining on-demand accessibility. The customer also benefits from a dedicated area within the warehouse tailored specifically to its inventory and fulfillment requirements. This dedicated space enables inventory management through workflows tailored to the customer’s business, creating a more organized and efficient operation that adapts as requirements evolve. The result is a warehouse layout that supports greater visibility, improved picking efficiency, and a stronger operational foundation for future growth.
Seamless ERP Implementation Through Collaboration
FFI partnered closely with the client throughout implementation and go-live to ensure a smooth transition. Following the launch, FFI helped troubleshoot system issues, address operational challenges, and make adjustments to maintain uninterrupted fulfillment operations. Through continuous communication and rapid feedback loops, both teams resolved issues quickly, minimized disruptions, and kept fulfillment operations running smoothly during the transition. In addition to supporting the ERP rollout, FFI implemented a streamlined process for integrating incoming order data. The improved workflow reduced manual entry, improved data accuracy, accelerated order transmission, and strengthened the connection between the customer’s ERP system and fulfillment operation. By combining operational expertise with a collaborative approach, FFI helped deliver a seamless ERP transition and establish scalable processes that support inventory visibility, order accuracy, and long-term fulfillment efficiency.
Supporting Complex B2B and DTC Fulfillment
In addition to direct-to-consumer (DTC) orders, FFI handles large distributor orders that require high levels of coordination, accuracy, and verification. These B2B shipments often consist of palletized orders containing hundreds of SKUs that must be picked, consolidated, verified, and shipped. The warehouse improvements implemented during the ERP transition helped create a more efficient process for managing these large orders while maintaining inventory accuracy and simultaneously fulfilling DTC orders. By combining organized storage, strategic product placement, and structured workflows, FFI can support both day-to-day fulfillment operations and complex distributor shipments from a single dedicated warehouse.
A Scalable Fulfillment Operation Built for Growth
Through strategic warehouse reorganization, data-driven inventory placement, dedicated storage space, enhanced order-processing workflows, and collaborative ERP implementation, FFI successfully scaled its fulfillment operations to meet evolving business demands. The result is a fulfillment operation that delivers greater inventory visibility, improved efficiency, and the flexibility needed to support continued growth in the competitive powersports parts market.