Production Planning
D2C
Multi-Warehouse

How Trtl brought clarity to a complex, global supply chain with AI-powered planning

The travel brand behind the viral neck pillow scaled from 300K to 500K annual volume while replacing spreadsheets with a single, connected AI system — enabling faster decisions, fewer stock issues, and thousands saved on freight — across six warehouses and multi-channel sales.

Industry

Consumer Goods

Travel accessories

Channel

D2C Multi-channel

Shopify, Amazon, TikTok

Use Cases

End-to-end

Demand, production, inventory, replenishment, cost, reporting

Previous Solutions

Spreadsheets

Excel, Microsoft Access

Background

Trtl designs innovative travel products used by millions worldwide. Known for its viral neck pillows, the company scaled fast - doubling volume in under two years, expanding its product range, and growing its footprint globally.

Behind the scenes, this rapid growth was straining operations. Trtl sells across Shopify, Amazon, and TikTok, and works with six 3PL partners, each managing multiple warehouses across regions. As volume surged, supply chain complexity skyrocketed, and planning became a constant firefight. “Just getting a clear view of sales, inventory, and forecasts across warehouses was a challenge”, recalled Gavin Donn, Trtl’s Supply Chain Lead.

Forecasting, production planning, inventory, and cost control had become increasingly difficult to manage across fragmented spreadsheets - especially with long lead times, multi-region fulfilment, and pressure to manage cash and stock ahead of peaks like Prime Day.

"
We’d just be hopping from one problem to the next, and not really making any decisions far enough in advance to prevent them. We went from around 300,000 pillows to 500,000 annually, and the complexity just ballooned. Trying to reduce stock and lead times while increasing availability - those three things don’t always go together.
GD
Gavin Donn
Supply Chain Lead

Dozens of off-the-shelf tools were evaluated - all fell short. They were either too rigid, too bloated, too expensive, or couldn’t handle Trtl’s multi-channel, multi-warehouse setup with the level of granularity needed.

Solution

Trtl chose Lumina to replace its manual processes with a connected, AI-driven planning system.

“Lumina centralised what was in my head and turned it into something the CEO can understand. It breaks down the data, makes it visual, and gets us the buy-in we need.” - Gavin Donn

Lumina’s flexibility meant Trtl could adapt the tool to fit their workflows, not the other way around. This wasn’t just another off-the-shelf forecast tool; it was a system built to reflect how Trtl actually works.

Key Features

Granular forecasting by SKU, warehouse, and sales channel, combining historical sales with top-down growth projections
Production planning and BOM views to plan further ahead and manage constraints
Proactive stock alerts and exception reports to catch risks early
Cashflow visibility through cost projections across time, category, and supplier
Replenishment automation with configurable lead times and constraints
Multi-region demand visibility that combines sales, inventory, and forecasts in one place
Leadership-ready views that support faster, better-aligned stock and cash decisions
On-the-fly analysis with AI to ask questions, explore scenarios, and uncover insights
Connectors to sales & warehouse system, cutting down manual data shuffling

Impact

Fewer
stock-outs & overstocks
with the right stock in the right locations
Faster
response
to shifting demand and underperforming SKUs
Clear
cost forecasts
to support confident purchasing decisions
Better
alignment
across supply chain, finance, and leadership
Thousands
of dollars saved
by avoiding emergency freight

The transformation has been remarkable. Since rolling out Lumina, Trtl has gained real-time visibility across its supply chain. Forecasting that once took days in Excel now happens instantly - more granular, more flexible, and easier to share across teams.

"
I’m not using a dozen spreadsheets anymore - just Lumina. I launched 40 SKUs recently and now I just go into Lumina and say: ‘Show me the sales last week.’ We saw one product underperforming and another selling out in the US, so we quickly adjusted our shipping strategy - switching from air to sea freight and saving a few thousand dollars.
GD
Gavin Donn
Supply Chain Lead

Lumina has become the foundation for smarter planning at Trtl - helping the team cut costs, reduce firefighting, and scale with confidence. With clearer visibility across stock, demand, and costs across regions, Trtl can make better, forward-looking decisions, faster. And by removing repetitive manual work and centralising fragmented data, Gavin and his team can focus on solving problems - before they happen.

Ready to move away from spreadsheet chaos?

Discover how Lumina's AI-powered forecasting can help you reduce stockouts, cut costs, and accelerate growth.