Supply chain planning: prepare your brand for holiday manufacturing
Supply chain planning becomes more critical during the holidays. Staff capacity gets stretched, shipping slows, and supply chains become unstable. To prepare your brand for holiday disruptions, focus on optimizing your inventory and manufacturing processes in advance.
Strong planning helps you avoid delays, control costs, and keep customers happy during peak demand. At THE/STUDIO, we help brands create custom products with reliable manufacturing and logistics support, so you’re ready long before the rush begins.
Key takeaways:
Build extra time into your production and shipping schedule.
Use data to forecast demand and manage inventory efficiently.
Diversify suppliers to avoid bottlenecks and shortages.
Partner with THE/STUDIO to find trusted manufacturers globally.
How to prepare your brand for holiday manufacturing?
The holidays can overwhelm even the best-run operations. Orders rise, carriers hit capacity, and suppliers juggle multiple clients at once. We work directly with vetted factories worldwide to help brands manage capacity, quality, and deadlines, especially during high-demand seasons.
To prepare your supply chain for holiday disruptions, you need early planning, clear communication, and flexible timelines. Here’s how to start:
Review last year’s sales and production data to predict demand.
Confirm supplier capacity and lead times before peak season hits.
Build backup plans for materials, labor, and shipping.
Communicate clearly with your entire team and logistics partners.
The goal is simple: avoid surprises, control costs, and deliver on time. Strong preparation now means smoother operations when it matters most.
Clear communication
Communication breaks down easily when everyone’s busy. Keep everyone aligned with frequent, simple updates:
Hold short, weekly check-ins with your team and suppliers.
Share production and delivery updates early, even if plans haven’t changed.
Use shared dashboards or project management tools for visibility.
When people know what’s happening, they can adjust quickly. Overcommunication helps prevent confusion, missed deadlines, and last-minute bottlenecks.
Start production earlier
During peak season, delays are normal. Plan as if everything will take longer than expected. Extra time gives you breathing room to handle unexpected issues without rushing or sacrificing quality.
Add at least 10-20% extra time to your production schedule.
Start manufacturing and packaging weeks before carrier cut-off dates.
Factor in possible customs delays for overseas orders.
Still not sure when to start your production? You can reach out to our support team for personalized assistance.
Adjust to shipping deadlines
Carriers change delivery windows and deadlines during the holidays. Missing one can delay shipments by weeks. Consider these tips:
Check each carrier’s holiday schedule early (UPS, FedEx, DHL, USPS).
Mark critical shipping deadlines on a shared team calendar.
Plan final shipments at least 3-5 days before cut-off dates.
If you ship globally, check international carriers too (some have earlier deadlines).
💡 Read more about holiday deadlines every brand should know.
Prepare for holiday surcharges
Shipping and handling costs increase during peak weeks. Surcharges can affect your margins if you’re not ready. Here’s what to do:
Review carrier announcements about seasonal surcharges.
Adjust product pricing or budget to include those extra fees.
Communicate changes with customers or partners in advance.
Quick tip: Compare carrier rates. Sometimes switching services saves more than absorbing surcharges.
Use order management systems
You can’t fix what you can’t see. Tracking every order in real time helps prevent lost shipments and delays. Best practices include:
Using an integrated order management system.
Providing customers with tracking updates automatically.
Setting up alerts for shipment delays or low stock.
Why does it help? Visibility builds trust. Your team and customers know where everything stands, reducing stress and last-minute chaos.
Partner with logistics experts
If shipping large volumes or managing complex routes, don’t go it alone. Partnering with a logistics expert has many advantages, beyond saving time and money:
Access to better carrier rates and shipping options.
Professional handling of customs, fulfillment, and warehousing.
Expert advice on managing returns and peak-season delivery.
Tip: Choose manufacturing partners with proven experience in retail and e-commerce logistics. They understand seasonal challenges and can scale with your demand.
How to optimize your supply chain for the holiday season?
Holiday operations run smoother when your supply chain is proactive, not reactive. Start with strong forecasting, extra inventory, flexible logistics, and automation. These steps reduce stress, cut costs, and keep customers happy even when demand surges. The key is preparation.
To build systems that can handle change without slowing you down, there are a few things you need to have in mind:
Forecast demand: Predicting sales is the foundation of supply chain planning. Review last year’s data, study current market trends, and include your upcoming promotions. Accurate forecasting helps you plan production schedules, order raw materials on time, and avoid stockouts or excess inventory during the busiest weeks.
Build stock: Identify your best-selling products and create a safety inventory to handle unexpected demand. Store this stock strategically (closer to your main customer regions or distribution hubs) to shorten lead times.
Flexible shipping: Holidays often bring shipping delays. Using multiple carriers or fulfillment centers gives you more options when routes or networks get congested. Offer flexible delivery speeds and consider regional distribution to improve responsiveness.
Automate inventory management: Automation keeps your supply chain efficient and accurate. Real-time tracking helps you monitor stock levels, trigger automatic reorders, and prevent overselling. Integrated systems also connect sales, production, and logistics teams, reducing human error and improving decision-making across your operations.
Tips for dealing with suppliers and vendors
Open communication with suppliers: Strong supplier relationships help you handle holiday pressure with fewer disruptions. Share forecasts and potential issues early. Regular check-ins help suppliers plan their resources and prevent last-minute surprises.
Diversifying suppliers: Don’t depend on just one source. THE/STUDIO connects brands with multiple vetted factories to reduce risk.
Negotiating lead terms: Discuss timelines and order flexibility before peak season. Clear terms on delivery dates and quantities keep your production schedule on track.
Frequently asked questions
What are the steps in supply chain planning?
The main supply chain planning steps include:
Demand forecasting to predict product needs.
Inventory management to balance stock levels.
Production planning to align factory output.
Procurement to source materials on time.
Logistics and distribution to ensure smooth delivery.
Supply chain planning involves coordinating all parts of your production and delivery process to meet customer demand efficiently. When done right, these steps help reduce costs, prevent delays, and keep your supply chain stable year-round.
What is demand planning in supply chain?
Demand planning is the process of predicting future customer demand using data, analytics, and market insights. It combines past sales, promotions, and seasonal trends to build accurate forecasts. This allows brands to produce the right amount of goods, reduce waste, and prevent stockouts.
How do seasons affect supply chains?
Seasonal changes can influence every part of a supply chain. Weather, holidays, and consumer behavior all shift production schedules and shipping patterns.
For example, winter storms can delay deliveries, while summer holidays may slow factory output. Planning ahead with flexible timelines and multiple suppliers helps reduce seasonal risks and keeps operations running smoothly.
Why are supply chain challenges tougher during the holidays?
During the holidays, e-commerce orders surge and shipping networks reach full capacity. Carriers, factories, and warehouses all face high demand at the same time.
Labor shortages and unpredictable weather make it worse. This combination leads to longer lead times, higher shipping costs, and more pressure on every link in the chain.
What supply chain challenges arise during the holiday season?
The busiest time of year brings unique challenges, such as:
Shipping delays and missed deadlines.
Rising air freight and transportation costs.
Warehouse space and labor shortages.
Extreme weather interruptions.
Unpredictable consumer demand spikes.
Which supply chain holiday seasons should you be aware of?
Major disruptions happen during Christmas, Chinese New Year and summer holidays.
Many factories in Asia shut down for weeks around the Lunar New Year, while summer brings reduced staffing and shipping delays in several regions.
How to prepare your brand for the holiday season?
Start planning months ahead. Begin by setting clear goals, such as improving delivery times or increasing sales. Identify key metrics like order accuracy, fulfillment speed, and customer satisfaction.
Create a holiday sales calendar to align marketing, design, and production efforts. Make sure your entire team knows the plan so your brand stays consistent and ready for peak season.
Final thoughts
Holiday success comes down to preparation and communication. A strong supply chain plan helps you stay ready for rising demand, limited carrier capacity, and shifting schedules. Start early, forecast sales, confirm production timelines, and build relationships with suppliers and logistics partners. The more visibility you have, the fewer surprises you’ll face.
During peak season, small delays can have big consequences. That’s why flexibility matters. Keep backup suppliers, plan extra lead time, and track every order closely. Focus on what you can control: communication, scheduling, and inventory management.
THE/STUDIO helps brands simplify holiday manufacturing with reliable global factories. When your operations are organized, you can adapt quickly and deliver on time. Planning ahead sets your brand up for smoother production, lower stress, and stronger customer trust all year long.
