The Apparel Group adds automation, crossdocking to new facility

At the Apparel Group’s new Texas distribution center, the company reduced handling costs and increased the speed of product to market—two items that are always in style.

By ·

When The Apparel Group Ltd. (TAG) sat down to design a new distribution center, it had two goals in mind.

One was to create an automated materials handling system that would get the job done with the least number of touches and the lowest possible handling cost.  Another was to build strategically by locating the facility in an area that would complement TAG’s West Coast cross-docking operations, allow its sales people to better serve its customers across the country and improve its customer service levels, especially the speed to market.

The 158,000-square-foot DC at the company’s U.S. headquarters in Lewisville, Texas, near Dallas, is a fashion success on both counts, says Kirk Longo, vice president of supply chain for the manufacturer, which also distributes men’s and women’s private label and branded clothing to retailers like Dillards, Kohl’s, Nordstroms and Lord & Taylor.

“This was a brand new facility that allowed us to build to suit our needs,” says Longo. “We were able to design a fulfillment center that meets our customers’ demand for smaller orders across the broad spectrum of SKUs we provide, maintain a high accuracy rate and do it with a lower cost per item of handling than at our previous facility in Kentucky. This was a team effort that required the skill of operations, engineering and information technology.”

Working with a systems integrator (Worldsource, 630-795-1100,, TAG implemented the first phase of the materials handling system in 2008, featuring:
• high-speed conveyor and sortation system,
• garment-on-hanger handling system and
• RF- and pick-to-light picking technologies.

click here to download the PDF article
Click here to download PDF article

About the Author

Bob Trebilcock
Bob Trebilcock, editorial director, has covered materials handling, technology, logistics and supply chain topics for nearly 30 years. In addition to Supply Chain Management Review, he is also Executive Editor of Modern Materials Handling. A graduate of Bowling Green State University, Trebilcock lives in Keene, NH. He can be reached at 603-357-0484.

Subscribe to Modern Materials Handling Magazine!

Subscribe today. It's FREE!
Find out what the world’s most innovative companies are doing to improve productivity in their plants and distribution centers.
Start your FREE subscription today!

Article Topics

Automation · Conveyors · System Report · World Source · · All Topics
Latest Whitepaper
Hydrogen, the Future of Materials Handling
Large, successful organizations are integrating hydrogen fuel cell technology into their lift truck fleets and benefiting from lower operational costs, reduced emissions and improved reliability.
Download Today!
From the October 2016 Issue
Brownells’ new Iowa distribution center has taken touches—and miles—out of the order fulfillment process and increased throughput with near 100% accuracy.
System Report: Brownells new DC is flexible and responsive
Pallet Usage Report: Pallets Remain Critical in the Modern-Day Warehouse
View More From this Issue
Subscribe to Our Email Newsletter
Sign up today to receive our FREE, weekly email newsletter!
Latest Webcast
Pallets: Supporting Product, Processes and the Enterprise
The smallest leak in performance or cost can bring a lean, nimble and speedy supply chain to a halt. During this 30-minute webcast we'll examine how Modern's readers use pallets to keep the wheels turning as they maneuver a road filled with sharp edges and potholes.
Register Today!
Brownells: Designing for Efficiency and Growth
Brownells’ new Iowa distribution center has taken touches—and miles—out of the order...
Industry celebrates National Manufacturing Day
Fourth annual Manufacturing Day is a grassroots effort by U.S. manufacturers to improve the public...

American Eagle Outfitters’ omni-channel journey
The fashion retailer has used warehouse execution software and automation to create a true...
The data-driven lift truck
Now that manufacturers and distributors are using the data from their automated systems to drive...