Case Study: Mary Kay Increases Pick Rates by 29% | Bastian Solutions

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

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.