Delta Galil ships 40M units with Warehouse Control and Pick to Light

Client: Delta Galil Industries is a leading global manufacturer and supplier of branded and private label apparel for men, women and children, with manufacturing and distribution facilities on four continents, serving retail giants such as Wal-Mart, Target, Kmart, JC Penny, and Marks & Spencer, and leading fashion brands such as Victoria’s Secret, Calvin Klein, Nike, Hugo Boss and Pierre Cardin.

Challenge: Delta Galil’s pickers were doing 2000 picks per day at 97% accuracy.  Due to exponential growth in customer demands, Delta Galil desperately needed to increase capacity and accuracy; however, they were limited by the footprint of their distribution center due to budget constraints.

Solution: To increase capacity and keep pace with growing customer demands, Delta Galil implemented AL Systems Warehouse Control System, Pick to Light and Productivity Management solution that could be scaled for future applications. Dynamic Picking was a key requirement, as Delta Galil needed the ability to allow more than one picker in a zone at a time. They also needed the ability to simultaneously pick orders for multiple customers in a given zone.

Results: Delta Galil more than doubled their productivity while significantly reducing the number of pickers required to fill orders. Delta Galil’s new minimum requirement for their pickers is 3500 picks per day at 99.5% accuracy. The system generates reports that provide insight into productivity and accuracy rates by picker and zone, allowing them to exercise corrective measures if necessary; however, they now average over 4000 picks at 99.95% accuracy and audit less than 7% of the orders. Delta Galil is geared to ship over 40 million units this year!