Black Week at 6x volume. On-time delivery didn't flinch
A sports supplements brand was growing faster than its packing room. When the Black Week forecast showed six times a regular week, the decision was simple: hand the parcels to a robot that packs one in 3 seconds and never gets tired.
A packing room that couldn't keep up with sales
The team packed in-house and coped for most of the year. The trouble started at the peaks: during Black Week, volume grew to six times a regular week, fulfillment stretched into days, and the inbox filled with "where is my parcel?" emails.
Adding people stopped working. Every extra pair of hands meant overtime, picking errors, and costs that ate the margin of the best sales week of the year.
A robot that packs a parcel in 3 seconds
We moved fulfillment onto Completio's robotic line: a carton cut to the product, closed and labeled in 3 seconds, with no fillers and no shipping air. The line's record is 1,257 parcels per hour, so a peak of this scale fits inside the capacity buffer, not inside overtime.
Orders flow in automatically from sales platforms, statuses update in real time, and orders placed by 8 PM ship the same day.
Fit-to-size packing: a carton matched to the product in 3 seconds
Capacity buffer for peaks: a line record of 1,257 parcels per hour
Orders placed by 8 PM ship the same day (D+0)
Order volume week by week. The on-time line never noticed the peak.
Results
For the first time in three years, nobody on the team packed parcels at night. The robot absorbed the entire peak, and we focused on selling.
How the rollout went
- T-8 wks
Volume audit and capacity plan
Sales history analysis, a 6x peak forecast, and a reserved buffer on the robotic line.
- T-4 wks
Integration and stock migration
Connecting the store to the WMS via Base took 3 business days. The rest of the week covered goods intake and test shipments.
- Black Week
The peak, live
Six times the volume flows through the line with no backlog. Orders placed by 8 PM ship the same day.
- After the peak
Season review
On-time delivery held at 99.97% OTIF, zero overtime on the client's side, and a capacity plan ready for next year.
