Mary Kay Case Study | Order Picking & Fulfillment

Maximizing Labor Efficiency with Intelligent Software

Mary Kay, one of the largest direct-selling companies in the world, implemented Exacta Intralogistics 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. 

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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


  • 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-pick-zone
  • mary-kay-supervisors-with-exacta
  • mary-kay-aerial-distribution-center
  • mary-kay-pick-to-light
  • mary-kay-picking-zones
  • mary-kay-indoor-aerial-picking-zone
  • mary-kay-exacta-hmi
  • mary-kay-exacta
  • mary-kay-fulfillment-center

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