Tandy Brands Accessories, Inc. was looking to amp up its picking operations to heighten throughput to major customers such as Wal-Mart and Target. The clothing accessory supplier, based in Dallas, Texas, decided that a pick-to-light system – compatible with its current warehouse management system – would give it just the right fit.

"We could not expand on the space we were allotted," says Kevin Koster, senior business analyst for the company. "Ramping up picking to accommodate higher volumes was our logical solution. Our philosophy is: Do more with less."

He continues to explain that the company made a major leap from its label-based picking philosophy, to a light-based system (PCC Systems, 262-251-3000).

"Our implementation timeframe was very tight. We had only three months to implement the software," says Tandy Brands senior vice president of information systems, Jim McMasters. "We quickly built a project team between [the supplier] and our IT department and our user workforce, and we were able to meet all of the deadlines of the project plan."

"There were a few quirks at first," he says, noting there was a substantial learning curve with the employees. "But once those things were ironed out, we were able to accommodate much higher volumes."

Koster says that with the old picking system, the company's two Texas-based DCs were averaging 170 lines per hour. That number now exceeds 300 per hour – and he expects even higher throughput going forward.

"We currently are expanding our South Texas facility and now we are adding 1,300 lights to the just over 600 we have in place," Koster notes. "As we go forward, I'm sure we'll add even more."