The Client: SaraMax Apparel Group, a high-volume supplier of merchandise to major retailers, is one of the largest privately held branded and private label undergarment manufacturers in the United States. In 2002, SaraMax relocated to a new distribution center for increased capacity and to enable the implementation of technology and practices to improve distribution operations.

Client Need: As a distributor to Wal-Mart, SaraMax adheres to strict vendor guidelines related to delivery schedules and accuracy. SaraMax desired the honor and benefits of making Wal-Mart's DSDC (direct store distribution center) supplier list. To make the DSDC list, SaraMax needed to improve its turnaround time and accuracy performance, and double its capacity. To meet the throughput and deadline requirements with paper-based practices, SaraMax would have incurred significant labor costs. In addition, SaraMax would have incurred even more labor costs, in audit personnel, to meet the accuracy requirements.

Solutions: SaraMax engaged AL Systems, and AL's sister business, W&H Systems, to provide a paperless picking solution. AL helped Saramax make the decision to implement light-directed picking technology, and real-time feedback audit stations, to process orders quickly, cost-effectively and accurately.

Results: Using AL's DynaPick Pick-to-Light solution (supported by conveyor and rack from W&H Systems), SaraMax intially processed greater than 50,000 units per 7.5-hour shift.  Today, SaraMax processes up to 75,000 units per shift at a continued accuracy rate of approximately 99.75% (before auditing). Using six audit stations, SaraMax audits between 10% of 50% of orders; orders are effectively fulfilled on a 100% basis. Three months after implementation, SaraMax was chosen to Wal-Mart's DSDC list.

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To learn more about how AL Systems helps customers improve distribution operations to achieve business objectives, contact us.