Optimizing Apparel Order Fulfillment – OPEX SURE SORT
Overcoming Manual Sorting Challenges in Apparel Warehousing to Meet Modern Demand with Scalable, Automated Solutions
Manual Apparel Order Fulfillment
The apparel industry faces increasing pressure to fill orders quickly, accurately, and at a lower cost to meet the growing demands of e-commerce and omnichannel retail. As consumer expectations shift towards rapid order fulfillment and returns processing, traditional manual workflows in apparel warehousing reveal limitations in handling high order volumes and complex SKU assortments. The OPEX Sure Sort system offers a transformative automated sorting solution uniquely designed to address these demands while optimizing resource use and minimizing labor costs.
Challenges Faced By Manual Operations In Apparel Order Fulfillment
Manual order fulfillment presents a range of challenges that hinder efficiency and impact the bottom line. Managing a high volume and large variety of SKUs is labor-intensive, and manual sorting and packing processes are slow and prone to errors. During peak seasons, labor demand surges, increasing costs and creating staffing challenges as temporary workers often require additional training and supervision. In addition, the manual process results in slower order fulfillment times, affecting the ability to meet consumer expectations for quick delivery. The frequent and complex returns typical in apparel add to the burden, as each item must be individually processed and sorted for potential restocking. This heavy reliance on labor for accuracy and speed elevates costs and increases the likelihood of errors, leading to customer dissatisfaction and costly returns processing.
33
reduction in temporary labor costs*
*Boux Avenue Case Study
2.1K
To achieve ROI
2
Elimination of manual order sortation at the distribution center*
How Sure Sort Can Transform Order Fulfillment in the Apparel Industry
The OPEX Sure Sort system revolutionizes warehouse apparel order fulfillment by automating sorting and order consolidation processes. When apparel items such as clothing, accessories, or shoes arrive at the warehouse, they are first inducted into the Sure Sort system through a conveyor, where each item is scanned for identification, capturing essential data like SKU, order ID, or destination. Based on this information, the system assigns each item to a specific sorting destination. The core of Sure Sort’s efficiency is its fleet of iBOTs, autonomous robotic vehicles that transport items rapidly and accurately within the system. These iBOTs operate with advanced motion algorithms, allowing them to move both vertically and horizontally to optimize sorting speed and space utilization. Each iBOT carries items to designated bins or chutes where orders are consolidated for packing.
To streamline the process further, Sure Sort uses pack-to-light indicators, which guide warehouse operators to retrieve items efficiently for final packing. This feature is especially helpful during peak periods, as it reduces the need for extensive training and minimizes errors by providing clear visual cues for order completion. Additionally, Sure Sort integrates seamlessly with the warehouse’s Warehouse Management System (WMS), allowing real-time updates on order status, inventory levels, and tracking data. This integration helps maintain inventory accuracy and supports fast, reliable order fulfillment with minimal manual intervention.
Labor Efficiency Reduce onboarding from two weeks to 15 minutes.
Enhanced Throughput Fulfill orders with five times the order pick rate per employee.
Scalability for Future Growth Grow without increasing operational complexity or costs.
The system’s modular design also enables scalability, making it ideal for apparel warehouses that experience seasonal demand shifts. During peak times, apparel companies can scale up operations by adding more iBOTs or expanding bin configurations to meet high throughput demands without additional labor. By automating the sorting process and achieving a processing capacity of 2,400 items per hour, Sure Sort significantly increases order fulfillment speed, reduces labor requirements, and minimizes errors, offering an effective solution for handling the diverse SKU varieties typical in the apparel industry.
Eran Gilboa
VP Logistics, Delta Israel
Benefits of Integrating Sure Sort into an Apparel Order Fulfillment Workflow
Integrating Sure Sort into apparel order fulfillment workflows delivers measurable benefits in efficiency, accuracy, and cost reduction. By reducing labor reliance, Sure Sort significantly lowers costs associated with temporary staffing and overtime during peak periods. For instance, Boux Avenue, a UK lingerie and swimwear brand, had a 33% reduction in seasonal labor requirements following Sure Sort implementation. Sure Sort’s single-pass sorting also enhances order accuracy, reducing errors and related costs in return processing. Delta Galil, a global leader in intimates and activewear, reported near-total elimination of common manual sorting errors, improving customer service quality and satisfaction. With Sure Sort, throughput is significantly increased, helping to meet customer expectations for faster delivery. Boux Avenue, for example, increased its orders fulfilled daily to over 10,000.
Meanwhile, OPEX’s collaboration with Bleckmann showcases how Sure Sort’s adaptability extends even further with RFID scanning integration. Facing challenges in scanning barcodes on product tags hidden within a poly bag, Bleckmann partnered with OPEX to develop and test the industry’s inaugural RFID scan tunnel. This innovative solution doubled Bleckmann’s sort rates and achieved a nearly 99% read rate, a dramatic improvement over previous scan tunnel technologies.
Sure Sort’s modular design allows it to scale with business demands without reconfigurations, making it an ideal solution for growing businesses. Additionally, the fast return on investment—often realized within two years—solidifies Sure Sort as a sound financial decision, providing long-term savings, enhanced operational efficiency, and positioning the warehouse for sustainable growth.
Did you know?
You can sort packing slips and shipping labels right into your shipping container with Sure Sort.
To save time, place larger items like puffer jackets or large sweaters at the base of each column to later consolidate with completed order above.
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