How Powerhouse91 Cut SLA Breaches by 89.88% Using Unicommerce
What Powerhouse91 Achieved Using Unicommerce?
5+ Million Inventory Count
SLA Breaches Reduced by 89.88%
100% Fulfillment Rate
SOI Growth Increased by 98.50%
About the Brand – Powerhouse91
Powerhouse91 is a brand-building and e-commerce operations partner that runs day-to-day commerce for multiple consumer brands. The team manages the entire flow from onboarding new products and managing hundreds of SKUs to tracking inventory, processing orders, coordinating logistics, and executing marketplace operations. Its brands operate across categories such as fitness and sports equipment, wellness and personal care, lifestyle accessories, and fulfillment materials, selling through Amazon, Flipkart, and brand-owned D2C websites.
As Powerhouse91 scaled, the operational setup became increasingly complex. With 100+ active SKUs, multiple warehouses, and orders flowing in simultaneously from marketplaces and Shopify stores, maintaining accurate inventory and fulfillment consistency became a challenge. Stock had to be visible in real time across locations, orders needed to be routed correctly, and SLAs had to be met across channels. This level of scale made it clear that Powerhouse91 needed a centralized system that could align inventory visibility, order processing, and fulfill execution at scale, that’s when they chose Unicommerce.
Key challenges Faced By the Brand
- Fragmented inventory Across Channels leading to Stockouts
Inventory was distributed across multiple fulfillment centers, marketplaces, and D2C platforms, creating visibility gaps that made it difficult to track SKU-level stock in real-time. Overselling was frequent due to misaligned stock pools, and manual reconciliation between warehouses and online channels slowed replenishment decisions. Without centralized inventory management, forecasting demand accurately and allocating stock efficiently became challenging, leading to lost sales especially during peak periods.
- Inefficient Order Processing Leading to Fulfillment Delays and Errors
Order management relied heavily on manual interventions and spreadsheet-based tracking, increasing the risk of picking, packing, and invoicing errors. High-volume sale days, such as festive or flash sale periods, often caused order-to-ship (O2S) delays. There was limited automation for order routing, batch allocation, or priority handling, forcing teams to spend extra time coordinating between warehouses and marketplaces, which impacted SLA adherence and overall operational efficiency.
- Inefficient Warehouse Workflows Causing Shipping Errors
Inbound processes, including PO receiving, GRN creation, QC inspection, and putaway, lacked standardized SOPs across fulfillment centers. Similarly, outbound workflows for picking, packing, manifesting, and dispatch were inconsistent, leading to higher error rates, inventory misplacement, and delayed shipments. The absence of structured warehouse operations also increased dependence on manual oversight and slowed the onboarding of new SKUs or brands.
- Returns and RTO Handling Inefficiencies Driving Higher Costs
Reverse logistics were largely reactive, with no structured process for return putaway, quality check, restocking, or reconciliation. Delays in updating returned stock caused inventory inaccuracies, sometimes resulting in overselling or blocked SKUs. Managing RTOs from multiple marketplaces further complicated reconciliation and led to slow customer refund cycles, impacting both seller cash flow and customer satisfaction.
- Limited Traceability and Compliance Gaps Resulting in Penalties
Maintaining SKU-level traceability across multiple warehouses and channels was complex, particularly for regulated products like menstrual care and hygiene items. Challenges included tracking batch numbers, expiry dates, and inward/outward movements, which increased risk during audits, cycle counts, and compliance reporting. Lack of a unified tracking system made it hard to ensure that saleable stock met regulatory standards, especially when fulfilling multiple marketplaces with strict quality requirements.
- Limited Integration Across Channels Leading to Operational Issues
Integrating new sales channels such as Zepto, Blinkit, BigBasket, and others required manual order creation, custom scripts, or partial API workarounds, slowing expansion and increasing operational overhead. Without a centralized system to manage orders and inventory across all channels, scaling up became resource-intensive, with higher chances of errors in allocation, dispatch, and stock blocking.
Solutions offered by Unicommerce
- Unified Inventory Management to Prevent Stockouts and Overstock
Unicommerce gave Powerhouse91 a single, centralized view of inventory across all sales channels and warehouses. Stock from every warehouse was managed in one system, with real-time updates and automatic inventory blocking once an order was confirmed, preventing overselling. This helped Powerhouse91 maintain accurate SKU-level stock visibility across both B2B and B2C channels and ensured consistent product availability on marketplaces and D2C websites. As a result, inventory mismatches were reduced, order cancellations due to stock issues declined, and fulfillment performance improved across channels.
- Optimized Order Fulfillment Process for Faster and Error-Free Delivery
A centralized order management system was implemented to automate and standardize order processing across channels. Orders from marketplaces and D2C websites flowed into a single system, where picklists, invoices, and shipping labels were generated automatically, reducing manual effort and errors. Barcode-based picking and packing improved accuracy, while automated order routing and facility allocation helped teams manage high-volume sale days more efficiently. This reduced order-to-ship delays, improved SLA adherence, and allowed Powerhouse91 to handle peak volumes without increasing operational complexity.
- Streamlined Warehouse Operations to Eliminate Inbound and Outbound Flows
A structured Warehouse Management System (WMS) was implemented to standardize both inbound and outbound operations across all fulfillment centers. Inbound workflows, including PO receiving, GRN creation, quality checks, and putaway were automated and guided by system-driven SOPs, ensuring accuracy and consistency. Outbound processes for picking, packing, manifesting, and dispatch were barcode-driven and aligned with predefined workflows, reducing errors and inventory misplacement. The WMS also simplified onboarding of new SKUs and brands, minimized manual oversight, and enabled faster, more reliable warehouse operations across locations.
- Enabled End-to-End Returns and RTO Management
A systematic reverse logistics workflow was implemented to handle returns and RTOs efficiently. Returned items were processed through barcode-enabled inwarding, quality checks, and condition-based putaway to ensure accurate restocking. Automated inventory reconciliation updated stock in real time, preventing overselling or blocked SKUs. Marketplace RTOs were integrated into the system for faster processing, enabling timely refunds and improving seller cash flow. These structured workflows reduced manual intervention, improved inventory accuracy, and enhanced the overall customer experience.
- End-to-End Traceability and Compliance Management
A centralized system was implemented to maintain SKU-level traceability across all warehouses and sales channels. Batch numbers, expiry dates, and stock movements were tracked in real time, ensuring that all inbound, outbound, and return flows were fully auditable. The system provided structured logs and reports to support regulatory compliance, cycle counts, and quality checks. This unified tracking enabled Powerhouse91 to ensure that all saleable stock met regulatory standards while fulfilling orders across multiple marketplaces, reducing risk during audits and improving overall inventory governance.
- Enabled Efficient Multi-Channel Expansion
A unified platform was implemented to manage orders and inventory across all sales channels from a single system. Marketplace-integrated channels like Amazon, Flipkart, and Shopify were synced automatically, while non-integrated channels such as Zepto, Blinkit, BigBasket, and others were handled through manual or API-based order creation within the same system. Centralized inventory updates, automated stock allocation, and standardized dispatch workflows reduced errors and operational overhead. This approach enabled Powerhouse91 to onboard new channels quickly, scale operations efficiently, and maintain accurate inventory and fulfillment across all platforms without additional custom development.
By centralizing inventory, orders, and warehouse workflows, Powerhouse91 gained real-time visibility and control across all channels and fulfillment centers. Standardized processes for order processing, picking, packing, returns, and RTOs reduced errors, sped up dispatch, and improved delivery timelines. Accurate stock updates and automated inventory blocking prevented stockouts and order cancellations, while structured returns management ensured faster processing and refunds. Together, these improvements enhanced customer trust, increased repeat purchase rates, and provided a strong operational foundation for scaling to new warehouses, channels, and regions without compromising service quality.
Impact on the Brand’s Growth
- Managed 5+ Million Inventory Count Complete visibility across warehouses and channels enabled precise stock tracking, reduced overstock and stockouts, and ensured optimal inventory allocation.
- 100% Fulfillment Rate Optimized order workflows, automation, and standardized warehouse operations ensured that all orders were processed and delivered accurately and on time, even during peak demand periods.
- SLA Breaches Reduced by 89.88% End-to-end monitoring, traceability, and compliance management minimized service disruptions, enhanced operational reliability, and strengthened customer trust.
- SOI Growth Increased by 98.50% Multi-channel integration, real-time stock updates, and scalable operations supported rapid growth in sales order items while maintaining accuracy and preventing errors.
By leveraging Unicommerce’s robust B2B and B2C operations platform, the brand could scale seamlessly, handle high order volumes without compromising service quality, and gain end-to-end operational control. These enhancements translated into higher revenue, improved customer satisfaction, and the ability to expand into new channels and regions confidently.