Frequently Asked Questions — Fulfillment & Warehousing
Q1: What do fulfillment services include versus just warehousing?
Fulfillment services go beyond storage: they receive and store your inventory, pick and pack orders, manage labeling, coordinate shipping, and handle returns. Warehousing is strictly the storage side until orders arrive.
Q2: What does “pick & pack” entail in a fulfillment operation?
Pick & pack is the process by which ordered items are retrieved (picked) from storage and then placed into shipping containers (packed), along with necessary packaging materials and documentation, before they’re shipped.
Q3: How does a pick & pack workflow typically operate?
- Orders flow in from your e-commerce system.
- Staff retrieve the items from shelving based on those orders.
- Retrieved items are inspected, packed into the correct box/mailer, and combined with packing slips or inserts.
- The package is labeled and forwarded to the shipping carrier.
- Order status and tracking are updated in your system.
Q4: What strategies are used for efficient picking in a warehouse?
Fulfillment centers often adopt one or a mix of picking methods, such as:
- Single-order picking — one order at a time
- Batch picking — grouping multiple orders to pick similar items together
- Zone picking — dividing the warehouse into zones; each picker handles a specific zone
- Wave picking — timed groups (“waves”) of orders that combine batch and zone methods
Q5: What costs should I expect in fulfillment & warehousing?
Common cost components include:
- Storage fees (by pallet, shelf, or cubic volume)
- Pick & pack or handling fees
- Receiving/inbound processing charges
- Packaging materials (boxes, fillers, labels)
- Shipping / carrier transit costs
- Optional or add-on services (e.g. packaging customization, returns, labeling)
Q6: How is quality and accuracy ensured in fulfillment operations?
Quality control is built in via:
- Inspection of goods upon receipt
- Use of barcode or scanning systems during picking
- Final checks before sealing the package
- Periodic audits and cycle counts to verify inventory accuracy
- Warehouse management systems (WMS) to track workflows and flag discrepancies
Q7: How scalable are fulfillment & warehousing services?
A reliable fulfillment operation can scale up or down: adding labor, expanding storage, or adjusting processes during peak seasons or growth phases.
Q8: How do fulfillment centers manage variable or seasonal demand?
They often use flexible staffing, buffer zones for overflow, and adjustable shift schedules to accommodate spikes or seasonal surges.
Q9: What is the typical turnaround or order processing time?
It depends on complexity, volume, and timing. Many fulfillment providers aim for same-day or next-day order processing when orders arrive before a cutoff time.
Q10: What does onboarding to a fulfillment provider look like?
Steps usually include:
- Sending over your inventory with proper labeling and prep
- The center receives, audits, and shelves the inventory
- Integration of your e-commerce/order system with the provider’s systems
- Establishing packaging preferences, shipping rules, and workflow
- Running test orders and then launching full operation
Q11: Do fulfillment operations handle returns and reverse logistics?
Yes, many providers include return handling: receiving returned items, inspecting them for resale, restocking or disposing as necessary, and providing return analytics.
Q12: How can a good fulfillment provider help reduce shipping costs?
They can:
- Consolidate multiple items into single packages
- Right-size packaging to avoid paying for empty space (dimensional weight charges)
- Use bulk or negotiated carrier rates
- Choose warehouse locations that reduce transit distance to your customers
- Negotiate with the major carriers for volume discounts
Frequently Asked Questions — Kitting & Co-Packing
Q1: What are kitting services and how do they work?
Kitting services refer to the process of grouping individual products or components and assembling them into one bundled unit (a “kit”) that ships as a single SKU. The service involves receiving parts, staging them, assembling, packaging, and preparing the kit for fulfillment.
Q2: What is co-packing and how does it differ from kitting?
Co-packing (contract packaging) typically covers packaging operations such as sealing, labeling, shrink wrapping, or assembling retail packs. Kitting is a subset of co-packing focused on bundling multiple items into one package. Co-packing may also involve finishing tasks to make a product shelf-ready.
Q3: What are the benefits of using kitting or co-packing services?
- Faster order processing (kits are preassembled)
- Fewer picking errors (less handling of individual items)
- Lower labor costs during fulfillment
- Reduced shipping costs through consolidation
- More appealing customer experience via neat bundles
- Better inventory control (kit as single SKU)
Q4: What types of products or industries are well suited for kits or bundles?
- Typical uses include subscription boxes, promotional gift sets, accessory bundles, starter kits, sampling kits, and multi-product offers in eCommerce or retail.Wave picking — timed groups (“waves”) of orders that combine batch and zone methods
Q5: What is the typical workflow for kit assembly (kitting)?
Common cost components include:
- Inbound receipt & inspection – Receive and inspect each component.
- Staging & organization – Place parts in an efficient layout for assembly.
- Assembly / kit building – Combine parts as per your configuration.
- Finishing touches – Add inserts, labels, or protective elements.
- Final quality check – Verify completeness and condition of each kit.
- Hand off to fulfillment – Move kits into inventory for packaging, pick & pack, or shipping.
Q6: Are there minimum order or kit quantity requirements?
Yes. Custom kits or those involving specialized packaging, inserts, or tooling may require minimum run quantities. Simpler kits may permit smaller batches.
Q7: How is quality control handled in kitting / co-packing? Quality methods often include:
- Checking incoming parts for defects
- Using assembly checklists or barcode scanning
- Performing spot inspections or full audits
- Conducting final verification before closure
Q8: Can custom packaging be included in your kitting services?
Absolutely. Kits can be housed in branded boxes, custom inserts, compartments, sleeves, or with decorative features — depending on your budget and presentation goals.
Q9: How scalable are kitting & co-packing services?
They can scale with your business. Providers can adjust labor, workflow lines, and facility space to handle small orders or high seasonal peaks.
Q10: How do kitting and co-packing help reduce shipping and fulfillment costs?
- Consolidation: multiple items ship as one package
- Right-sizing packaging: limiting empty space and avoiding dimensional weight charges
- Less handling & fewer pick cycles: fewer steps in order processing
Q11: What do I need to supply to a kitting/co-packing provider to start? You’ll typically need to pr
- All kit components (products, accessories, literature)
- Assembly instructions or a kit manifest
- Packaging preferences or specifications
- Target quantities and timelines
- Information about how kits will be fulfilled or shipped
Q12: Do kitting services integrate directly into fulfillment operations?
Yes — kitting and co-packing often link seamlessly with fulfillment. Once the kit is assembled, it enters the pick & pack flow for shipping, eliminating unnecessary transfers or handling.