The Brand
Dirt Bike Kidz is a direct-to-consumer ecommerce brand selling gear and products for young riders and the families behind them. Shipping happens in batches every 3 to 4 days, with volume typically running between 100 and 200 orders per week, spiking higher around product releases.
For a small operation shipping on that cadence, every batch has to move efficiently. When volume climbs around a new release, the team needs to be able to absorb that pressure without adding people or hours.
The problems that surfaced in the old workflow were predictable:
- Picking without clear bin locations meant backtracking and searching
- Manual box selection slowed packing and created extra decisions for seasonal staff
- Comparing rates in Shopify added time and friction to every shipment
- A full batch could run from a few hours to a full day depending on who was on shift
Like a lot of small ecommerce operations, Dirt Bike Kidz didn't need a warehouse management system or a complex multi-platform stack. They needed a shipping workflow that removed the manual decisions and let one person run a batch cleanly.
How VESYL Made the Difference
The biggest shift wasn't just faster label printing. It was removing the decisions that were adding time to every single order, box selection, rate comparison, location guesswork, and the extra coordination required when seasonal help was in the mix.
Before VESYL, a batch at Dirt Bike Kidz required:
- Manually pulling product locations without a clear warehouse guide
- Choosing the right box for each order based on experience or guesswork
- Logging into Shopify Shipping and selecting a carrier rate manually
- Printing secondary documents to reference bin locations and product information
- Running 1 to 3 people through the same repetitive steps, regardless of volume
That kind of workflow is manageable when volume is steady and the team knows the warehouse. It creates friction fast when a product release spikes orders or seasonal staff need to get up to speed quickly.
With VESYL, Dirt Bike Kidz moved to a streamlined workflow where the shipping decisions are handled by the system, and the team focuses on physically moving orders through the warehouse.
"We used to need two or three people to get through a batch, and it could take most of the day. With VESYL, one person can handle the same volume in half the time. The difference is immediate."
— Drew, Warehouse Manager, Dirt Bike Kidz
What Changed in the Workflow
- Pick tickets now carry bin locations: Before VESYL, adding product locations into the Shopify backend was not a simple process. VESYL prints bin locations directly on the pick ticket, so whoever is picking knows exactly where to go without cross-referencing a separate document or relying on memory. Pick time decreased and backtracking dropped.
- Box assignment became automatic: Manually deciding which box to use for each order was, in the team's own words, a tedious process, particularly with seasonal staff who didn't have the same instinct a regular operator would. With automatic box assignment in VESYL, the correct box is assigned to each shipment automatically. Packing became faster and second-guessing, re-packing, and manual errors decreased.
- Rate selection stopped being a manual task: Dirt Bike Kidz had been manually selecting shipping rates in Shopify Shipping for every order. VESYL's rate shopping pulls USPS and UPS rates automatically and selects the best available option without requiring the team to compare or decide. That step is gone from the workflow entirely.
"Before VESYL, manually selecting rates, choosing package sizes, and printing separate pick tickets for locations made every batch more complicated than it needed to be. Now that's all handled."
— Drew, Warehouse Manager, Dirt Bike Kidz
The Net Impact
One person can now run a batch that previously required two or three, and the same volume that once stretched to a full day now gets done in roughly half the time.
In Summary
Dirt Bike Kidz didn't just speed up their shipping. They removed the manual layers that were making every batch harder than it needed to be.
By moving from Shopify Shipping to a VESYL-powered workflow, Dirt Bike Kidz:
- Cut fulfillment time per batch by approximately 50%
- Reduced the team required for a typical batch from up to 3 people to 1
- Eliminated manual rate selection with automated rate shopping across USPS and UPS
- Built a repeatable picking and packing process that works with seasonal staff, not against them
This is what efficient fulfillment looks like for a small team running real volume: fewer decisions, fewer touches, and a workflow that holds up when orders spike.
Ready to Modernize Your Shipping Workflow?
If your warehouse is still manually selecting rates, choosing boxes order by order, or relying on institutional knowledge that doesn't transfer to seasonal staff, you're not alone.
VESYL helps ecommerce brands reduce fulfillment time, cut labor hours, and build shipping workflows that run cleanly without a full warehouse team.
Book a demo to see what your workflow could look like with the manual decisions removed.
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