CHALLENGE SOLUTION

CLIENT

Phillips-Van Heusen Corporation

Jonesville, North Carolina

Phillips-Van Heusen Corporation is the largest shirt manufacturer in the world and a leading apparel and footwear company. Its well-known brands include Van Heusen, IZOD, G.H. Bass, as well as licensing agreements with Geoffrey Beene, Arrow, DKNY and Kenneth Cole.

CHALLENGE

In 1993, to maintain superior inventory control while meeting the varied distribution demands of both apparel and footwear, PVH installed a Mantissay Tilt Tray Sortation shipping system at its Jonesville, NC facility. With its acquisition of Calvin Klein, Inc. in 2003, PVH faced the challenge of increasing its ability to effectively distribute a much expanded range and variety of product without compromising its operations and customer service. Flexibility, versatility and the ability to accomidate dynamic shifts in product mix were paramount in PVH's search for a solution.

SOLUTION

Based on both current and projected distribution requirements at the Jonesville facility, Mantissa was once again selected to develop a system solution to address not only current needs but also potential growth plans. The packing conveyor and sortation system incorporates 8000' of conveyor handling full and partial cases in waves from case pick modules at a rate of 48 cases per minute. The cases are transported on a conveyor loop, which feeds the manual induction areas and a future wave staging area. This loop also services both the Hot Pick and Value Added Services areas, located in the workspace under the tilt tray sorter. At the induction areas, poly-bagged apparel, boxed shirts and shoe pairs, all without unique barcodes, are removed from cases and manually inducted onto a 668' Scorpiony tilt tray sorter utilizing a Destination/MerlinPlus distribution process, featuring a visual decrementing prompt.

All 128 packing chutes utilize Mantissa's exclusive AardvarkTM Technology, which maintains orientation of the product while directing it to one of the four destinations within each chute. The Aardvark device is designed to accomidate a diverse range of product including, shoe boxes and poly-bagged apparel. Product is accumulated in each destination of the chute module, and then indexed to floor level where it is packed out into cartons, automatically sealed, weighed, labeled and transported to shipping. The integration of both Mantissa sortation systems not only meets, but exceeds all current requirements and positions Phillips-Van Heusen for future business growth.

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