For consumer brands shipping from their own warehouse

Your warehouse is costing you more than it should. I'll show you exactly how much.

One week inside your operation. A plain-English report on what's leaking money, what to fix first, and what it's worth in dollars.

Book a free 30-min call No pitch. Real advice either way.
Ran a warehouse myself as CEO of a consumer brand 3 clients at a time, by design English & Japanese, native in both
Does this sound familiar?

Shipping works. It just never feels under control.

01You couldn't say what it actually costs to ship one order.
02Wrong items ship out. Each one costs you a re-ship, sometimes a customer.
03Everyone's busy all day. Orders still pile up during peak weeks.
04The system says one stock count. The shelf says another.
05New inventory sits for days before it's actually sellable.
06You suspect it could run better. You're too deep in it to see where.

None of this means your team is bad. It means nobody's ever measured it properly. That's the job I do.

Warehouse aisle with stocked pallet racking
What you get out of it

Ship more. Waste less. Same team.

More orders out the door

Better layout, clearer process. Your current team gets more done without working harder.

Fewer mistakes

Every wrong shipment costs you twice. We find why mistakes happen and remove the cause.

Hours back every week

Wasted motion and double-handling quietly eat your team's day. We measure it, then remove it.

Every problem priced in dollars

Not "you could be more efficient." A number: what it's costing you per year.

A team that likes the new way

Less chaos, clearer days. Your staff keep the system after I leave.

A straight answer

In-house or outsource? I sell neither, so you get an honest one.

Not a report that sits in a drawer. An operation that ships more, costs less, runs calmer, with numbers to prove it.
Packing and labeling orders by hand
What I actually look at

Plain questions, measured properly.

What does one order really cost you, start to finish?
How many orders can one person handle in an hour?
How often does the wrong item ship, and what does that cost?
Do your stock counts match what's actually on the shelf?
When stock arrives, how long until it's ready to sell?
Are your boxes the right size, or are you paying to ship air?
Could your setup survive a week at double the volume?
How it works

Look first. Fix second. Stay light, third.

1

Free call

30 min

Tell me how your operation runs. You leave with real advice either way.

2

The audit

2–3 weeks · fixed fee

A week on your floor. A written report: what's leaking money, what it costs per year, what to fix first, and an honest in-house vs. outsource verdict.

3

I run the fixes

2–3 months, if you want

I work alongside your team until the new way sticks. Then I leave. The process stays with your people.

4

Monthly check-in

optional

A short review each month so it doesn't quietly drift back.

The audit pays for itself

Hire me to run the fixes, and the audit fee is credited in full against that work.

Book a free 30-min call Come with your order volume and your biggest headache.
Who's doing the looking

An operator, not a slide-deck consultant.

Hiroo Kato moving pallets in a shipping container with a pallet jack

I'm Hiroo Kato. I was President and CEO of the U.S. arm of a Japanese consumer wellness company, where the warehouse wasn't a chapter in a textbook. It was my Tuesday. I've packed the boxes, hired the team, and answered to a head office about all of it.

So when I walk your floor, I'm looking for the things that used to keep me up at night, and I know what they cost because I've paid for them. I take three clients at a time, because this work happens in person, not from a template.

Ran U.S. operations end to end Built a consumer brand from zero Native English & Japanese Based in Southern California
Warehouse packing room with stocked shelving and staged orders
Common questions

Things people ask before booking.

Will this disrupt my team's work?
Barely. I'm mostly watching normal work happen and asking short questions. Never a performance review of your people, I say that to your team on day one.
What do you need from us?
Floor access for about a week, your order and inventory numbers, and some time with the people who do the shipping. Messy records are fine. That's usually finding number one.
How much does the audit cost?
One fixed price, agreed before we start. No hourly billing. I'll give you the number on our first call. If you hire me to run the fixes after, the audit fee is credited against that work.
We're pretty small. Is this for us?
Order count alone doesn't tell the story, your average order size matters more. As a rough guide, the audit makes the most sense around $3M or more a year through your own warehouse. For a supplement brand with a $50–100 order size, that's usually 5,000 to 10,000 orders a month. Smaller than that, book the free call anyway, I'll tell you honestly if a full audit isn't worth your money yet.
What if you find nothing wrong?
Then you get written proof, with real numbers, that your operation runs well. Genuinely useful. In honesty, I've yet to find a warehouse with nothing worth fixing.
Our head office is in Japan. Can you work with them?
Yes, natively. I'm bilingual and I've spent years reporting U.S. operations to a Japanese head office, in both languages.
One free call. Real advice.

Find out what your warehouse is really costing you.

30 minutes. Bring your monthly order volume and your biggest shipping headache.

Book a free 30-min call Prefer email? hiroo@hernsconsulting.com
Client slots: 2 of 3 open