CASE STUDY 2: Supply Chain Optimization

Problem:
As global vendor networks expanded, inefficiencies emerged across communication, timelines, and production accuracy. Relying on manual updates and email-based tracking led to missed details, production delays, and costly rework. A lack of integrated systems made it difficult to monitor performance or forecast issues, slowing down decision-making and production lead times.

Strategy:
Develop a custom production system designed to eliminate bottlenecks and enable automated workflows to consistently meet a three-week production lead time at scale.

Execution:

  • 1. Custom Order Fulfillment System

    Designed and implemented a streamlined order processing system for made-to-order wetsuits, capable of fulfilling domestic orders in three weeks and international orders in four. Automation between platforms reduced friction and improved tracking across production stages.

    • Integrated multiple tools using API automation (Shopify, Trello, Airtable).

    • Reduced order processing delays with real-time data syncing.

    • Created visibility across fulfillment stages for all team members.

  • 2. Automated Pattern Generation

    Reduced pattern creation time from one hour to five minutes by automating the proprietary garment patterning process. This improved speed and reduced manual labor while maintaining precision.

    • Built a Google Script system that converts order inputs into patterns.

    • Used Zapier to automate communication between tools.

    • Enabled consistent and rapid pattern delivery to production.

  • 3. ERP and WMS System Integration

    Connected Katana ERP with Shopify and Soapbox WMS to centralize production tracking and vendor communication. Enabled real-time forecasting and tighter control over inventory and fulfillment.

    • Real-time syncing of order and inventory data.

    • Automated vendor updates on material needs and production statuses.

    • Improved material planning accuracy and reduced stockouts.

  • 4. Centralized Communication and Production Planning

    Developed an Airtable-based platform to unify internal and external production planning. This helped coordinate B2B and D2C workflows, filled production gaps, and smoothed demand spikes.

    • Unified contractors, vendors, and internal teams under one system.

    • Created automated production calendars based on capacity.

    • Reduced scheduling conflicts and improved responsiveness.

Results

  • Delivered thousands of made-to-order wetsuits while maintaining a consistent 3.5-week production and delivery lead time.

  • Improved product margins by 5.6% by automating the pattern-making workflow, reducing creation time from one hour to five minutes.

  • Reduced operating expenses by 45% through workflow automation and optimized resource allocation, allowing the team to stay lean without sacrificing performance.

  • Increased company revenue by 50% by integrating B2B production orders into the master production calendar, balancing capacity, avoiding production gaps, and preserving D2C performance.