Full Workflow of U.S. Fulfillment Warehouses: 5 Key Steps from Inbound to Final Delivery   ----- 2025-06-20 11:10

With the rapid growth of cross-border e-commerce, U.S.-based fulfillment warehouses have become an essential component in optimizing logistics and enhancing customer satisfaction. From inbound processing to doorstep delivery, every phase requires precise coordination. Below are the five key stages of the U.S. warehouse fulfillment process:


1. Inbound Receiving & Inspection

a. Inbound Appointment

Sellers must schedule delivery slots in advance via the Warehouse Management System (WMS), providing detailed shipment information including SKUs, quantities, weights, and dimensions. This helps the warehouse prepare for unloading and space allocation.

b. Quality Inspection

Upon arrival, warehouse staff verify the physical shipment against the packing list, check for external damage (e.g. torn packaging, moisture), and perform either spot-checks or full inspections—especially for fragile or high-value items.

c. System Entry & Shelving

Using barcodes or RFID technology, product data is bound to specific storage locations, ensuring precise inventory tracking. Items are then shelved or palletized based on attributes like product category or sales frequency.


2. Inventory Management & Optimization

a. Real-Time Monitoring

The WMS continuously updates inventory levels, helping sellers avoid stockouts and identify slow-moving SKUs for clearance.

b. Smart Storage Strategies

  • High-frequency SKUs: Stored near packing stations in “hot zones” to minimize picking time.

  • Large or irregular items: Placed on custom racks or floor-stacked for secure storage.

c. Cycle Counting & Audits

Regular cycle counts or full audits ensure physical inventory matches system data. Most warehouses aim for a discrepancy rate of less than 0.5%.


3. Order Processing, Picking & Packing

a. Order Sync & Allocation

The WMS integrates seamlessly with e-commerce platforms like Amazon, TEMU, or SHEIN to pull orders in real time. The system then assigns optimal picking routes.

b. Accurate Picking

Warehouse staff use handheld terminals to scan barcodes during picking, with system validation to ensure the correct SKU and quantity—reducing risks of mispicks or missing items.

c. Custom Packing

Packaging materials (bubble wrap, boxes, eco-fillers) are selected based on product characteristics. Invoices, return labels, and other necessary documents are included. Some warehouses also offer custom-branded packaging, such as logo stickers.


4. Outbound & Last-Mile Delivery

a. Shipping Method Selection

Based on delivery timeframes (e.g., next-day, standard), the system matches orders with carriers like USPS, UPS, or FedEx. It automatically calculates shipping fees and generates labels.

b. Parcel Consolidation & Loading

Packages are grouped by delivery region. Automated sorters (like cross-belt systems) improve efficiency and reduce human error in the loading process.


Conclusion (Optional for Blog Use)

Efficient overseas warehouse operations are a cornerstone of global e-commerce success. By mastering each stage—from inbound to last-mile delivery—sellers can streamline logistics, reduce costs, and provide faster, more reliable service to U.S. customers.