Subscribe to our free, weekly email newsletter!


Pick-to-light improves productivity for Delta Galil

Pick-to-light technology increases productivity and picking accuracy for global manufacturer and marketer of high-quality apparel.
By Lorie King Rogers, Associate Editor
December 15, 2010

For Delta Galil Industries, a global manufacturer and supplier of apparel for men, women and children, increasing accuracy and capacity was a must to keep up with increasing customer demands.

“Our pickers were doing 2,000 picks per day with paper,” explains Steven Seidman, vice president of supply chain at Delta Galil. “We were auditing 100% of the orders due to 97% pick accuracy. We desperately needed to increase capacity and accuracy without increasing the footprint of the distribution center.”

Delta has manufacturing and distribution facilities on four continents, serving retail giants such as Wal-Mart, Target, Kmart and J.C. Penney, and leading fashion brands including Victoria’s Secret, Calvin Klein, Nike, Hugo Boss and Pierre Cardin.

And with more than 40 million items shipping a year from its Willamsport, Pa., DC, a new system was critical. Delta tossed out its paper picking system and implemented a warehouse control system
with pick-to-light and productivity management that could be scaled for future applications (AL Systems, http://www.alsystems.com). Dynamic picking was a key requirement, as Delta needed to accommodate multiple pickers in a zone at one time. The system also provides associates with the ability to simultaneously pick orders for multiple customers in a given zone.

Since implementing the system, Delta more than doubled productivity and significantly reduced the number of pickers required to fill orders. Delta’s new minimum requirement for pickers is 3,500 picks per day at 99.5% accuracy. The system generates reports that measure productivity and accuracy rates by picker and zone. However, associates now average more than 4,000 picks at 99.95% accuracy and audit less than 7% of the orders. “We achieved payback on our implementation in about 13 months,” says Seidman. “We were expecting an 18-month ROI, but did much better due to the dramatic increase in productivity and accuracy.”

About the Author

image
Lorie King Rogers
Associate Editor

Lorie King Rogers, associate editor, joined Modern in 2009 after working as a freelance writer for the Casebook issue and show daily at tradeshows. A graduate of Emerson College, she has also worked as an editor on Stock Car Racing Magazine.


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!

Recent Entries

Crown invited me to its flagship service center outside Chicago for a demonstration of their operator and technician training programs. Prepared for plenty of PowerPoints and goofy videos, I instead experienced two full days of hands-on, grease-covered, eye-opening and tremendously exciting education.

PwC CEO survey finds only 19% of top retailers say they can fulfill omni-channel demand profitably.

Seegrid’s former director of development from 2003-2007 returns to the company.

March shipments came in at 988,065, which easily eclipsed February by 24 percent, as well as March 2014 by 19 percent. Panjiva said total first quarter shipments at 2,580,899 were 4 percent ahead of the first quarter of 2014.

Diligent monitoring of battery inventory can cut waste, boost battery performance and lifespan, and increase productivity.