Challenge

Low-margin B2B orders; production not built for high-mix, high-volume personalization.

Solution

• Launched three Etsy stores aimed at high-demand niches (custom pet socks, face masks, etc.).
• Photoshop scripting auto-generated thousands of product mock-ups.
• Pipeline: Etsy → PM board → offshore design team → API-driven print-sheet nesting with embedded order # & barcode.
• Barcode scan triggered one-touch print of label, manifest (box-size logic), and invoice; final scan closed order and pushed tracking to customer.
• Production floor split by printer role for flow-through efficiency.

Impact

• #1 ranking in every targeted Etsy Canada category during peak Christmas season; dominated first-page results across all three stores.
• Margin per unit up 2–3× versus wholesale jobs.
• Hundreds of unique orders/day with <5 % error rate.
• Pick-pack time cut ~70 %; shipping cost optimized by auto-box selection.
• DTC now delivers the majority of gross profit while wholesale continues uninterrupted.

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