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.
image
By Lorie King Rogers, Associate Editor
December 15, 2010 - MMH Editorial

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 Logistics Management magazine

Subscribe today. It's FREE!
Get timely insider information that you can use to better manage your
entire logistics operation.
Start your FREE subscription today!

Recent Entries

At last week’s NASSTRAC Conference in Orlando, Fla., LM Group News Editor Jeff Berman caught up with Jack Holmes, president of UPS Freight, the less-than-truckload subsidiary of UPS. On June 30, Holmes will retire from UPS after a 37-year career with Big Brown that saw him rise from the overnight docks in Philadelphia to the executive suite in Richmond, Va.

Having introduced into the California State Senate a new bill designed to give an exemption from sales and use tax for port terminal operators purchasing zero or “near zero-emission” equipment, Lara is trying to advance two agendas.

The notions of “green shoots” or “cautious optimism” in gauging the current state of the economy does not specifically exhibit what is really happening, when assessing how things are actually going, it seems. That was made clear by Bob Costello, chief economist at the American Trucking Associations, at last week’s NASSTRAC (National Shippers Strategic Transportation Council) Shippers Conference and Transportation Expo in Orlando, Fla. last week.

With a 6.8 cent gain to $2.266 per gallon, this week’s average diesel price is at its highest level since the week of December 28, when it was at $2.237 per gallon.

Manufacturing activity in April remained on the right side of growth for the second straight month, following six months of contraction, according to the April edition of the Manufacturing Report on Business from the Institute for Supply Management (ISM).

Comments

Post a comment
Commenting is not available in this channel entry.