RTO occurs when a delivery attempt fails (customer not available, refusal at delivery, wrong address, fake order) and the package is returned to the seller's warehouse. Cost includes: 2x shipping (forward + return), locked working capital, repackaging labor, and inventory write-down.
For Indian D2C with high COD share, RTO rates run 12-25% — a large portion of revenue lost. Prepaid orders have 1-3% RTO; COD averages 18-22%. The difference is the entire economic impact of accepting COD.
Reducing RTO: WhatsApp/SMS verification before dispatch, address auto-correction, RTO prediction ML (Shiprocket, Pickrr), incentivize prepaid (5-10% off for prepaid).