Scaling Chaos into Clarity: How Ramp Helped a Pet Food Brand Triple Warehouse Efficiency Amid Rapid Growth

Background:

When a fast-growing pet food eCommerce brand saw their annual revenue surge from $30M to $75M in under two years, their warehouse operations buckled under the pressure. Orders were delayed. Inventory was mismanaged. Labor costs spiked. And customer satisfaction started to slip—right when brand loyalty was most critical.

They didn’t have a demand problem. They had an operational one.

That’s where Ramp Advisory came in.

The Challenge: A High-Growth Brand Without a Scalable Organization Structure

Like many DTC eCommerce businesses in hypergrowth mode, the client had outgrown their original warehouse setup and lacked warehouse efficiency at their current size. Their fulfillment center—originally designed to handle modest order volume—was struggling to support surging SKUs, same-day shipping expectations, and fluctuating seasonal demand.

Inventory was stored inefficiently. Pick-and-pack workflows were inconsistent across shifts. There was no clear labor model or capacity planning framework. Systems didn’t talk to each other. The result: an expensive, chaotic operation held together by manual workarounds and heroic effort.

The client knew they needed structure. What they didn’t need was a bloated solution that couldn’t flex with their growth.

Ramp’s Approach: Build Once, Scale Forever

Ramp started with a deep diagnostic—on-site warehouse walks, labor time studies, throughput analysis, and interviews with frontline operators and leadership. We weren’t just looking for problems. We were looking for the right leverage points—the small changes that would unlock major performance gains.

From there, we developed a three-phase plan:

1. Redesign the Floor for Flow: We re-mapped inventory zones to reduce travel time by 40%, introduced visual management tools to reduce picking errors, and built replenishment logic to keep fast movers stocked and accessible.

2. Standardize the Work: Ramp created clear SOPs for receiving, putaway, picking, packing, and returns—then trained the team on execution and embedded accountability loops. This drove consistent quality across all shifts and reduced training time for new hires by 60%.

3. Create a Scalable Labor Model: We introduced a demand-based staffing framework tied to weekly order forecasts, allowing leadership to flex headcount without over- or under-staffing. This slashed overtime costs and improved team morale.

We didn’t stop there. Ramp helped implement lightweight WMS enhancements, created custom dashboards for real-time ops visibility, and established a monthly warehouse performance review cadence with leadership.

The Result: A Warehouse Built to Scale

Within six months, the brand had transformed its fulfillment center into a strategic growth enabler. The results speak for themselves:

• Order accuracy rose to 99.7%

• Labor efficiency improved by 35%

• On-time shipping performance jumped from 82% to 97%

• The warehouse supported a 150% revenue increase—without major capital investment

Most importantly, the leadership team finally had a warehouse operation they could trust to scale with the brand—not hold it back.

Warehouse Efficiency Drives Commercial Growth

At Ramp, we believe the backend of your business is just as important as the brand your customers see. Because when operations run smoothly, growth isn’t

just possible—it’s sustainable.

Need to build a warehouse operation that grows with you? Book time here.