An online retailer faced campaign peaks that overwhelmed pack stations and slipped linehaul departures. The response aligned overflow waves and scan discipline to WMS cut-offs.
Challenge
Campaign volumes exceeded pack station capacity with parcels floor-stacked and linehaul departures slipping. Chargeback disputes increased when scan evidence was inconsistent at induction.
WMS cut-offs were not aligned with carrier induction windows.
Approach
An afternoon overflow wave, dimension checks at induction, and milestone scans were aligned to WMS cut-offs. Campaign weeks used pre-agreed volume bands by lane.
Exception reviews ran daily during peak with a single escalation contact at the fulfilment centre.
Outcome
Campaign weeks cleared within planned windows and chargeback disputes fell due to consistent scan evidence. Operations could see backlog risk before linehaul closed.
The overflow model is now standard for promotional calendars shared four weeks ahead.
Services used
Metro freight, consignment tracking, and account visibility.