Anyone who sleeps through peak season preparation risks delivery delays, overloaded warehouse capacity and, in the worst case, unhappy customers. In this article, we show what matters most in fulfillment planning for the end of the year – and how an experienced fulfillment and production service provider like bergler industrieservices GmbH can help.
Why preparation should start now
The fourth quarter places very different demands on warehouse and logistics processes than the rest of the year. Order volumes rise sharply, delivery times are expected to be shorter, and at the same time the quality of picking and packaging has to be right. Anyone who only starts planning in October or November has little room left to organize additional capacity or adjust processes.
A look at the typical bottlenecks shows where acting early makes the difference.
- Warehouse capacity – Is the existing storage space sufficient for increased stock volumes?
- Picking – Can order peaks be handled without loss of quality and within a reasonable time?
- Packaging – Are the packaging processes efficient enough for high volumes, and do they meet current legal requirements?
- Shipping – Is the connection to shipping providers reliable even at high volumes?
- Returns management – Return rates rise noticeably after Christmas in particular – is a process in place for this?
Realistically assessing the right capacity
The first step in peak season planning is an honest assessment of the expected order volume. Historical data from the previous year, your business's current growth figures, and a look at planned marketing campaigns that could trigger additional demand all help here.
This makes it possible to work out how much additional storage space, staff or packaging capacity is actually needed. A rough rule of thumb that has proven useful in practice is to add a safety buffer to the expected peak volume when planning staff and space, rather than calculating with the plain average figure alone.
Testing processes early instead of waiting for the real thing
A common mistake in practice is only putting new processes or additional capacity into operation once peak season begins. It makes more sense to run a test in September or early October to identify bottlenecks, sources of error or communication gaps while order volumes are still manageable.
This applies in particular to:
- Connecting new or additional shipping providers
- Automated picking processes that should be tested under real load
- Coordination between the warehouse, customer service and returns department during periods of higher volume
Don't leave returns management planning until January
A wave of returns regularly follows the Christmas shopping season, and it's often underestimated. Anyone who only sets up returns management once the first parcels start coming back risks long processing times and capital tied up in goods that haven't been restocked.
Thoughtful returns planning includes clearly defined inspection and restocking processes, sufficient staff and space capacity for the period after Christmas, and transparent communication with customers about return deadlines and conditions.
Keeping an eye on legal requirements
Beyond pure capacity planning, it's also worth looking at current regulatory requirements for packaging, for example regarding material efficiency and recyclability. Such requirements can affect the choice of packaging material and size and should be factored into planning early, rather than creating pressure to adapt shortly before peak season.
In summary, the decisive success factor for peak season isn't the peak season itself, but the preparation in the months beforehand.
"A successful peak season isn't decided in November, but in the months before. Anyone who realistically assesses capacity, tests processes early and factors in returns management from the start goes into the busiest time of the year noticeably more relaxed."
Raimund Bergler, Managing Director of bergler industrieservices GmbH
Anyone who tackles these points now gains a noticeable head start once orders climb steeply again in the fourth quarter.
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