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

While it feels somewhat hard to fathom, the stage is set for the Council of Supply Chain Management Professionals (CSCMP) Annual Conference in San Antonio, Texas.

Carload volumes were up 1.4 percent at 300,388, and intermodal volume for the week ending September 13 was up 5 percent at 279,052 trailers and containers.

Company says the Cloud offering allows customers to respond more quickly to new business opportunities, without significant upfront cost and implementation times.

As e-commerce continues to take a bigger piece of the holiday package delivery pie, it stands to reason that companies need to be proactive and prepared in order to deliver premium service during the busiest time of year, which is rapidly approaching. And that is exactly what transportation giants UPS and FedEx are doing this year. How are they doing it exactly? The primary step they are taking is to up their numbers of seasonal staffers.

A recent hearing of the Subcommittee on Coast Guard and Maritime Transportation suggests that the U.S. Merchant Marine industry may be poised for a major comeback.

Comments

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