Apparel Brand Eliminates Size/Color Mis-Picks

Result: 99.9% Pick Accuracy

A fast-growing apparel label struggled with size and color mix-ups under a generalist 3PL. PapayaShip's SKU-level slotting and polybagging workflow, built specifically for fashion inventory, brought pick accuracy to 99.9% and cut returns from wrong items by more than half.

The Challenge

An apparel brand sells the same style across multiple sizes and colors, which look nearly identical on a shelf. Their previous 3PL slotted inventory by style only, leading to frequent size and color mis-picks that drove returns and one-star reviews.

Our Approach

PapayaShip re-slotted the brand's entire catalog down to the individual size/color SKU level, with each variant in its own bin and barcode-scanned at pick. Items are polybagged immediately after picking to prevent mix-ups before packing.

Results

• Pick accuracy reached 99.9%, up from an estimated 92% at the prior 3PL
• Returns attributed to wrong size or color cut by more than half
• Customer reviews mentioning shipping mistakes dropped to near zero
• New seasonal styles onboarded into the slotting system within 48 hours