Mary Kay

Exacta Supply Chain Software Case Study

Business Objectives

  • Replace and update existing 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 Mary Kay's host information and manifest system.
Mary Kay

Maximizing Labor Efficiency with Intelligent Software 

Mary Kay, one of the largest direct-selling companies in the world, implemented Exacta: Supply Chain Software and a new light-directed picking system to boost hourly picking rates by 29% and maximize labor efficiency. Employees experience a more ergonomic workplace while supervisors now have access to key warehouse data in real-time. 


Key Technologies

  • Single level pick module using pick to light systems for high volume, broken case picking
  • Bastian Solutions' Exacta warehouse control system for inventory control
  • Interface between the ExactaWCS: Warehouse Control System  and Mary Kay's ERP system
  • Automated pack process 
  • Exacta PTL Human Machine Interface (HMI) allows real-time visibility for supervisors
Mary Kay Exacta HMI

Exacta: Supply Chain Software


See the results

29% increase in operator pick rates due to ergonomic improvements and 100% system up time.

Prior to system updates, Mary Kay averaged 650 units picked per operator per hour. Now operators are averaging 840 units picked per hour.

This equates to an average of 525 lines per operator per hour. Since filming, Mary Kay has further improved throughput by 46%, reaching 768 lines per operator per hour.

Increased operator job satisfaction due to system reliability, ease of use, and ergonomic design.

The ExactaWCS: Warehouse Control System and smooth integration with Mary Kay's existing information system will help Mary Kay reach their growth goals.

Mary Kay DC with Light Directed Picking

Picking Zones


Photos of our solution

Interested in Maximizing Labor?
See more information on Exacta Supply Chain Software and contact us!