A Journey from College Startup to Industry Leader

P-Jammy’s story isn’t just about selling apparel—it’s about evolution. What started as a small resale business in a college dorm room has grown into a leading name in pop culture apparel and sleepwear. Levi Nelson, co-owner of P-Jammy and Seven Times Six, has seen the entrepreneurial endeavors transform over the last two decades, from flipping books and DVDs to securing major licensing deals with Warner Bros., Disney, and Marvel.

Yet, growth comes with challenges. At one point, P-Jammy’s inventory was spread across eight to ten storage units, multiple warehouse locations, and rental spaces. This fragmented system made fulfillment complex and inefficient.

“We had, I think it was eight to 10 storage units. We were renting a little bit of a warehouse space across the street from the new building. And then we had another warehouse out by the airport. It was just all over.”

This scattered approach was limiting their ability to scale, and they knew a change was needed.

The Turning Point: Facing a Storage Crisis

By the time P-Jammy moved into a 60,000-square-foot warehouse, they expected to have enough space for years of growth. However, they quickly realized they had miscalculated their storage layout.

“When we got into the new warehouse, we put the racks up however we thought they should be. And we quickly realized that we must’ve done something wrong because we were running out of space already.”

Realizing they needed a better approach, they connected with HOJ Innovations for a warehouse design study. The goal was clear—optimize the space, improve efficiency, and eliminate the need for external warehouses.

Redefining Storage: From Pallets to Bins

One of the most impactful changes from Hoj’s design study was shifting from traditional pallet storage to a carton-based system. This transition allowed for better organization, increased accessibility, and more efficient picking.

“At first, it threw us for a loop. We always thought you had to be a pallet company. But we knew something had to change because we had just moved into a brand-new 60,000-square-foot warehouse, and we were already out of room.”

By restructuring their storage layout, P-Jammy nearly doubled its inventory capacity.

“Just from your guys' study, we used to fit 1.3 million units in the warehouse. After we implemented your system, we fit around 2.1 or 2.2 million units. And then we made a few tweaks, and now we have 2.5 million units in our warehouse.”

Eliminating Inefficiencies: The End of "The Chase"

Before implementing a structured warehouse system, P-Jammy’s fulfillment process was chaotic, particularly during peak seasons. Employees often had to scramble to locate missing items, a process they called "The Chase."

“The Chase was basically: you come in in the morning, do your normal procedure, and get all your orders out the door. But at the end of the day, we’d still have 100, 200, sometimes 600, 700 items left. And we’d have to send everyone scrambling to find them.”

This inefficient process caused frustration, long hours, and lost productivity. However, with a well-optimized warehouse layout and better inventory tracking, "The Chase" was eliminated entirely.

Transforming Picking & Shipping Efficiency

Before the redesign, picking was a slow, manual process. Employees had to navigate multi-tiered pallet racks, often using order pickers to retrieve individual items. The shift to a bin-based picking system streamlined picking operations, allowing workers to quickly access high-demand SKUs from lower, more accessible shelves.

“The old system had our pickers averaging about 50 orders an hour. After we implemented WarehouseOS and the new layout, our average jumped to 100 an hour, with some reaching 120-130 an hour.”

Shipping speed also saw a dramatic improvement.

“Shipping used to take forever. Before, we were averaging 20-30 packages an hour per station. Now, our top performers are hitting 140 an hour.”

How Technology Changed the Game

A major factor in P-Jammy’s efficiency boost was implementing WarehouseOS, a warehouse management system designed to streamline operations.

“In order to talk about WarehouseOS’s benefits, you have to look at all the problems it solved. Number one was paper. We used to have paper pick lists, and I’d find them lying around on the floor all the time.”

The system’s iPad-based interface eliminated paperwork, reduced errors, and introduced real-time tracking.

“I can tell you exactly where every order is at any given moment. If a customer cancels, I can find the order on aisle five with Isaiah picking it, and stop it before it ships. We never had that kind of control before.”

Reducing Costs: No More Overtime or Excess Temps

With improved efficiency, P-Jammy significantly reduced labor costs.

“This was the first year where we didn’t pay overtime to any of our employees because we got everything done on time. We also didn’t need 20 to 30 temps like in previous years. We only used a temp agency for a couple of days.”

Even temporary workers could be onboarded quickly thanks to WarehouseOS.

“In the past, we had to train temps in October for them to be ready by December. With WarehouseOS, we could bring someone in the same day, train them in five minutes, and they’d be up and running.”

Gamifying the Process: Employee Motivation Through Leaderboards

One of the unexpected benefits of the new system was employee engagement. By introducing a leaderboard in the warehouse, employees became motivated to improve their performance.

“The leaderboard gamified shipping. Employees could see their names move up and down based on performance. It wasn’t about punishing anyone—it was about making work fun. Some of our temps even made it onto the leaderboard, competing with full-time employees.”

The Future: Scalable Growth Without Storage Concerns

With an optimized warehouse and an efficient fulfillment process, P-Jammy is positioned for significant growth.

“We have no reason to get another warehouse. Even if we double or triple our business, we’ll be fine. We’ve got plenty of space, and with WarehouseOS, we can handle any volume increase without adding storage.”

Looking ahead, they may expand to an East Coast facility to reduce shipping costs, but they’re confident in replicating their current system.

“The only way we’re getting a new warehouse is if it’s on the East Coast to save on shipping. And even then, we’ll implement the exact same system.”

Lessons for Other Businesses

P-Jammy’s journey offers valuable lessons for businesses facing fulfillment challenges:

1. Evaluate Your Storage Strategy – If you’re running out of space, rethinking your layout can be more effective than expanding.

2. Leverage Technology – Paper-based systems create inefficiencies. Implementing a digital warehouse management system improves accuracy and speed.

3. Eliminate Bottlenecks – Processes like "The Chase" waste time and energy. Identify and eliminate inefficiencies in your workflow.

4. Optimize Labor Costs – A well-structured warehouse reduces reliance on temporary workers and overtime.

5. Embrace Change – Transitioning from pallets to bins required a mindset shift, but it led to massive improvements.

P-Jammy’s transformation is proof that even rapidly growing companies can scale efficiently with the right strategies and tools.