Fashion & Apparel — Automated sortation of 8,500+ SKUs across 350 retail locations
Manual sorting of 8,500+ SKUs across 350 retail stores. Error rate 3.2%, throughput only 450 pcs/h, seasonal peaks caused massive overtime. The brand struggled to keep pace with fast-fashion cycles, and mis-sorts led to stockouts at key retail locations during critical selling periods. Labor costs were spiraling, and the existing manual processes could not scale to meet growing demand.
MGM Cross Belt Sorter with 150 destinations, integrated WMS, and automated induction. The system was deployed in modular phases to minimize disruption to ongoing operations. Intelligent batching algorithms grouped similar SKUs for efficient sortation waves, while gentle handling mechanisms ensured zero garment damage throughout the sorting process. Real-time inventory visibility was achieved through seamless WMS integration.
The modular design allowed a phased rollout across distribution centers, minimizing operational disruption and enabling the team to validate each phase before expanding. This approach de-risked the project and accelerated user adoption.
Customized belt surfaces and controlled acceleration/deceleration profiles eliminated garment damage entirely. The brand saw zero product loss due to sorting, preserving high-value inventory integrity.
Seamless integration with the existing warehouse management system provided real-time inventory tracking, automated replenishment triggers, and end-to-end visibility from induction to store delivery.
The system easily handled 3x volume spikes during seasonal peaks without additional labor. Dynamic wave planning and intelligent batching ensured consistent throughput regardless of order complexity.
Contact our team to discuss your logistics challenges and discover how MGM can transform your operations.
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