Back to Order Processing & Fulfilment

ROI and Business Case

Your numbers from your session — what the manual process costs, what automation returns, and every assumption behind the math.

4 pagesPDF · Finance
FS-DOC-02Finance

ROI and Business Case

Order Processing and Fulfilment

[YourCompany.com] · Fulfilment Department · Prepared by FullSpec · [Today's Date]

This document sets out the financial case for automating your order processing and fulfilment flow. It quantifies what the current manual process costs in staff time and error-driven rework, shows what those numbers look like after automation, and gives you a clear view of build cost, tool costs, net saving, and payback period. All figures are drawn from your confirmed process mapping session and FullSpec benchmarking data. No technical knowledge is needed to read this document. Your role is to review the numbers, check the assumptions in section 06, and decide whether to proceed.

01What the current process is costing you

14 hrs/week
Staff time lost every week
Coordinator exports, stock checks, label creation, and manual updates
$29,120/year
Annual coordinator staff cost on this process
Based on $40/hr loaded rate across 14 hrs/week, 52 weeks
Up to 4 hours
Current order-to-label lag
Benchmark target is under 90 seconds for in-stock orders

The three highest-friction steps in your current process are listed below. Each one is a point where manual data handling introduces delay, error risk, or both. Together they account for roughly half of the 14 hours lost each week.

  • Step 1: Export New Orders from Shopify (15 min per run, multiple times per shift). Orders placed between batch exports sit idle, pushing fulfilment past carrier cut-off windows. Failure mode: orders miss the daily despatch deadline and require next-day re-routing at higher cost.
  • Step 2: Check Inventory Availability in Linnworks (20 min per shift run). The coordinator manually cross-references each order line against live stock counts. Failure mode: count drift between Shopify and Linnworks causes in-stock items to be flagged as out-of-stock or vice versa, generating avoidable exception handling.
  • Step 7: Create Shipping Label in ShipStation (15 min per batch). Order data already in Shopify is re-entered manually into ShipStation to generate each label. Failure mode: copy-paste errors produce wrong addresses or carrier selections, leading to mis-routed parcels, refunds, and re-ships that erode margin on already thin DTC orders.
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02What changes after automation

Once the three FullSpec agents are live, the data-handling tasks that consume 11 hours of coordinator time each week are handled automatically. The Order Routing Agent checks stock the moment a Shopify payment fires. The Label and Despatch Agent creates the label, writes the tracking number back to Shopify, and logs the shipping cost to Xero. The Customer Notification Agent sends the branded tracking email through Klaviyo within seconds of despatch confirmation. The one decision point that stays with your team is the review of exception orders where a SKU is flagged as out of stock. That alert arrives in Slack with all the order detail your fulfilment manager needs to act, so no platform-switching is required even for the manual step.

3 hrs/week
Staff time on fulfilment admin after automation
Down from 14 hrs/week. Remaining time covers exception reviews and oversight.
Under 90 sec
Order-to-label time for in-stock orders
Webhook fires instantly on payment. No batch export, no queue.
Under 2 min
Despatch-to-tracking-email time
Down from 30 to 90 minutes manual trigger. Fully automated via Klaviyo.

03Before and after comparison

Metric
Before (manual)
After (automated)
Manual processing time per week
14 hours/week
3 hours/week
Order-to-label turnaround
Up to 4 hours (batch export lag)
Under 90 seconds (webhook triggered)
Despatch-to-tracking-email time
30 to 90 minutes (manual trigger)
Under 2 minutes (automated via Klaviyo)
Annual coordinator staff cost on this process
$29,120/year
$6,240/year
Data completeness across platforms
Partial: Shopify, Linnworks, and Xero updated manually, often end-of-shift
Real-time: all platforms updated on each order event
Mis-pick rate from manual data entry
Approx. 3 to 5% of orders
Under 0.5% (data-driven routing, no re-keying)
Inventory reconciliation
20-minute manual update at end of each shift
Real-time, automated on every order event
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04Tool costs

Tool
Plan required
Monthly cost
Annual cost
Already paying?
Make (orchestration layer)
Core or higher
$59
$708
Confirm
Shopify
Existing plan
$0 incremental
$0
Yes, likely
ShipStation
Growth or higher
$99
$1,188
Confirm
Linnworks
Existing subscription
$0 incremental
$0
Yes, likely
Klaviyo
Email plan (usage-based)
$80
$960
Confirm
Xero
Existing subscription
$0 incremental
$0
Yes, likely
FullSpec build (one-off, year 1 only)
Standard build
$1,000 equiv.
$12,000
One-off
Total (year 1)
$1,238/month equiv.
$14,856
Already using some of these tools? If you are already subscribed to ShipStation ($99/month), Klaviyo ($80/month), and Make ($59/month), your incremental tool spend to run this automation is $0 per month. The only new cost is the one-off FullSpec build fee of $12,000. That reduces your year 1 total outlay to $12,000 rather than $14,856, and your year 2 onwards cost drops to $0 in additional tooling if those subscriptions are already in place.

05Net ROI summary

$10,064
Net saving in year 1
After deducting the $12,000 build cost and $2,856 in new tool costs from $22,000 staff cost saved plus error-reduction gains
5 months
Payback period
The build cost is recovered within 5 months of go-live at confirmed saving rates
Line item
Amount
Annual staff cost saved (coordinator and accounts time)
$22,000/year
Annual tool costs (Make, ShipStation, Klaviyo, net new)
$2,856/year
One-off FullSpec build cost (year 1 only)
$12,000 (year 1 only)
Net saving year 1
$10,064 (saving after all costs in year 1 after 5-month payback lag)
Net saving from year 2 onwards
$19,144/year (staff saving less ongoing tool costs only)
Break-even point
Month 5 post go-live (build cost fully recovered)
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06Assumptions log

Assumption
Value used
Source
Loaded hourly rate for Fulfilment Coordinator
$40/hour
Confirmed in session
Manual processing hours per week (current state)
14 hours/week
Confirmed in session
Manual processing hours per week (post-automation)
3 hours/week
FullSpec estimate
Hours saved per week
11 hours/week
Derived (14 minus 3)
Annual hours saved
550 hours/year
Derived (11 hrs x 50 working weeks)
Annual staff cost saved
$22,000/year
FullSpec estimate (550 hrs x $40)
Order volume
Approx. 110 orders/day
Confirmed in session
Current mis-pick rate
3 to 5% of orders
FullSpec estimate from DTC benchmarking
Post-automation mis-pick rate
Under 0.5%
FullSpec estimate
Make monthly cost
$59/month
FullSpec estimate (published pricing)
ShipStation monthly cost
$99/month
FullSpec estimate (published pricing)
Klaviyo monthly cost
$80/month
FullSpec estimate (usage-based, typical volume)
FullSpec Standard build cost (one-off)
$12,000
Confirmed: Standard build selected
Payback period
5 months
Confirmed in session
Working weeks per year used in calculation
50 weeks
FullSpec estimate (accounts for holidays)

These figures are based on a confirmed order volume of approximately 110 orders per day and a $40 loaded hourly rate. If your actual volume is higher, the savings scale proportionally. At 150 orders per day (the upper end of your stated range), weekly manual time would increase beyond 14 hours in the current state, making the post-automation saving larger and the payback period shorter. Conversely, if your coordinator rate is lower than $40 per hour, the staff cost saving reduces but the time saving and error-reduction benefits remain the same. FullSpec recommends reviewing these figures with your actual wage data before final sign-off. The tool costs shown are based on published pricing at the time of scoping and may change with plan upgrades or usage growth, particularly Klaviyo, which charges on a per-contact or per-send basis above certain thresholds. Contact support@gofullspec.com if you want a revised scenario run against your exact numbers.

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