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
Your Guide to Voice for the Warehouse
Is voice a good fit for my operation? How would voice work in my warehouse? With the help of the Vitech Guide to Voice, you can find all the answers to your voice questions in one place.
Download Today!
From the October 2017 Modern Materials Handling Issue
An early adopter, Rochester Drug Cooperative is using robotic piece-picking technology to complement picking of slow-moving items. System report for Rochester Drug Cooperative, Robotic picking and inventory management, Innovative distribution center robotics solutions , IAM Robotics case study
Injecting agility into WMS implementation
The Big Picture: Business as Unusual
View More From this Issue
Subscribe to Our Email Newsletter
Sign up today to receive our FREE, weekly email newsletter!
Latest Webcast
The State of the DC Voice Market
A lot has changed in the last 10 years, especially in voice technology. This webinar will cover the state of the voice market, review two leading voice solutions and help you gain a better understanding of the options and capabilities available today.
Register Today!
EDITORS' PICKS
Rochester Drug Cooperative: Robots ready for work
It’s still early stages, but Rochester Drug Cooperative is proving that mobile robotic piece...
Manufacturing Day: 2,716 events from Hawaii to Alaska to Puerto Rico
Events to be scheduled throughout the month, so the remaining 249,185 manufacturing firms in the...

System Report: Pouch sorter powers Stage’s fulfillment needs
How a hometown department store chain transformed its e-fulfillment processes with pouch sortation...
Cubing and Weighing Equipment: Measure Up
The use of cubing and weighing equipment is growing beyond dimensional weight applications.