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 ·

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.”

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


About the Author

Lorie King Rogers
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!

Article Topics

AL Systems · Pick to Light · Picking · Retail · Technology · · All Topics
Latest Whitepaper
Sorting Out Your Sortation Options
Guiding you through the process of evaluating and selecting the right “mission-critical” sortation solution
Download Today!
From the April 2017 Issue
How does a fastgrowing, e-commerce startup company build out order fulfillment capabilities? Thrive Market answered that question with its new facility in Indiana.
2017 Warehouse/DC Equipment Survey: Investment up as service pressures rise
Putaway 101: Everything in its Place
View More From this Issue
Subscribe to Our Email Newsletter
Sign up today to receive our FREE, weekly email newsletter!
Latest Webcast
2016 Warehouse/DC Operations Webcast: Confronting omni-channel complexity
During this webcast we’ll examine the current activities, trends, and best practices in warehouse and DC operations management and how companies plan to address complex issues associate with omni-channel fulfillment.
Register Today!
EDITORS' PICKS
ProMat closes: Make your plans for Modex 2018
With a record number of exhibitors and attendees seen at ProMat 2017, MHI anticipates more of the...
Keynote: Magic is the result of over-preparation and over-delivering to customers
During his keynote presentation Wednesday afternoon, Earvin “Magic” Johnson told a packed...

Keynote panel confirms digital supply chain shift seen in new MHI study
Wednesday’s keynote panelists agreed it is time to embrace the shift to digital supply chains seen...
MHI to honor original products, solutions with 5th-annual Innovation Awards
On Wednesday, during MHI Industry Night with Dana Carvey, the winners of the 5th-annual MHI...