Apollo Scooters frequently bundled free accessories (valued at ~$100) with scooter purchases during pre-order sales. While the accessories had a low product cost, the shipping and handling process created major inefficiencies:

• Warehouse staff had to open each scooter box, insert the accessory, and re-tape the package, wasting significant time.

• Mistakes often occurred, with the wrong accessories included or missed altogether.

• If an accessory was out of stock, scooters were shipped first, and accessories were sent separately later — costing an extra $20–$40 per shipment.

I identified a more efficient approach: accessories could be shipped as separate packages within the same order, at a cost of only $3–$5 extra per accessory shipment. Even better, shipping labels could be generated in advance and used later when stock arrived, without additional overhead.

This meant:

• Scooters could remain on pallets, shipped without ever opening or repacking boxes.

• Accessories could be shipped separately, either together with the scooter or later once in stock, without causing delays for customers.

• Warehouse operations became much faster, as staff only needed to apply shipping labels rather than re-handle inventory.

• Shipping errors were eliminated, since scooters were no longer unpacked and accessories were managed separately.

The new process reduced both labor costs and shipping expenses, while significantly improving customer experience by ensuring scooters shipped on time, with accessories following seamlessly.