The Client: A leading children's clothing retailer in the U.S. with over 600 stores, and with annual sales over $500 million.

Client Need: This client experienced dramatic growth in the 90's and needed automation to maintain the volume demands of its growing store base. The prior operation was manually intensive and prone to errors. They turned to AL Systems to install a light-directed packing system customized to their waving operation.

Solutions: AL Systems installed four packing modules capable of servicing 800 stores. Each store location contains an 8-digit LED display and AL's DynaPack manages the store order request and the fulfillment process. The flexibility designed into this solution allows the client to process duplicate routes simultaneously or all stores at once. With the use of RF technology, they can track all production activity of each packer and pack zone.

Results: This client can turn store orders in less than 24 hours and achieve over 99.7% accuracy. Store cartons are filled to capacity to optimize shipping costs. The flexibility of processes allows them to adapt to surges in volume without additional labor costs. Packer productivity average 650 units per hour.

To Learn More:  To learn more about how AL Systems helps clients improve distribution operations in order to achieve business objectives, contact us.