The Challenge Bare Escentuals once filled orders for spas and retail store boutiques using paper pick lists and carts. Carts were pushed through the warehouse by operators, one discrete order at a time. Each operator picked about 85 pieces per hour, not including packing. A dedicated team was used for packing the orders at a rate of approximately 110 pieces per hour, per operator. When peak season occurred, order fulfillment time became extended and the company had to pay for expedited shipping service to meet promised delivery dates. To improve this warehouse logistics configuration that serves 200 retail store boutiques and 1400 spas, Bare Escentuals implemented an all new process for picking split case items. Our Solution The centerpiece of the picking solution consi

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