Mary Kay Case Study

System Summary

Mary Kay has grown from a small direct sales company to the largest direct seller of skin care products and the best-selling brand of facial skin care and color cosmetics in the United States.

Mary Kay Canada partnered with Bastian Solutions to automate its Mississauga, Canada distribution center.

Business Challenge

• Update system technology by replacing outdated pick-to- light system without affecting ongoing operations.
• Increase order fulfillment throughput capacity.
• Provide an ergonomic work environment for the staff.
• Achieve higher accuracy in picking and labeling of orders to enhance customer service levels.
• Growth capability for additional throughput requirements over the next 5 to 10 years.
• Smooth integration with the Mary Kay's host information and Manifest system.

Key Technologies

• Single level pick module using Pick to Light systems for high volume broken case picking.
• Bastian's Exacta  Warehouse Management System for inventory control.
• Bastian's Exacta Connect interface between the Warehouse Management System and Mary Kay's ERP system.
• Automated pack process Automod warehouse simulation for validation and bench marking.

Results

• Operator pick rates improved 25% due to ergonomics and 100% system up time.

• Operators are happy due to system reliability, ease of use, and ergonomic design.

• Bastian's Warehouse Management System solution and smooth integration with Mary Kay's existing information system will help Mary Kay reach their growth goals over the next 5-10 years.