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Reducing the Number of Manual Touches

Gap Inc. & TGW Logistics

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Fashion Logistics

Gap Inc. Hits New Performance Levels with TGW Logistics

Blue square logo of the fashion expert GAP Inc. Blue square logo of the fashion expert GAP Inc.
North America and Canada

Automated Material Handling

Gap Inc. has grown from a single retail store in 1969 to one of the largest fashion retailers in the world and includes the brands Gap, Banana Republic, Old Navy, and Athleta. When Gap wanted to reduce the number of manual touches across their distribution centers for more efficient operations, they partnered with TGW Logistics. Over the past eight years, Gap has invested in automated material handling in their U.S. fulfillment centers in Fishkill, Fresno, Gallatin, and Groveport, as well as their Canadian fulfillment center in Brampton.

A Milestone in Material Handling

Gap’s retail and ecommerce orders in North America are handled through decentralized distribution centers. They decided to automate when they noticed their manual processes leading to slowdowns and inefficiencies.  

To optimize inbound logistics and storage processes, Gap invested in automated solutions that reduced the number of touches by seven compared to manual systems. With automated goods receiving, operators only need to unload trailers before products are ready to be picked for customer orders. 

Gap set a milestone for operational performance, leading them to upgrade seven North American distribution centers.   

Video teaser for the GAP case study that highlights the benefits of automation in the distribution center Video teaser for the GAP case study that highlights the benefits of automation in the distribution center
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Benefits of Automation

  • One-Touch Receiving

    Gap eliminated manual touches before picking with One-Touch Receiving - reducing costs while improving the speed and quality of their fashion logistics.

  • Automated Material Handling

    Finding enough operators for their fulfillment centers was a challenge. Using our automated solutions for material handling, inbound logistics now relies less on labor, leading to uninterrupted operations even during peak times.

How TGW Logistics Made it Possible

Fast & Efficient Operations with One-Touch Receiving

By implementing One-Touch Receiving, our standardized inbound storage system for material handling and goods receiving processes, Gap saw a return on their investment in less than two years and eliminated seven of eight manual touches. Cartons are unloaded from the truck and placed directly on an extendable conveyor belt before quality inspection and scanning. Once in the system, a conformity check compares delivery quantity with order quantity. Cartons are stored and retrieved with a mini-load system consisting of 11-meter tall, high-performance cranes, which ensure a cost-effective single carton handling, avoiding labor-intensive operations.

Improved Sorter Replenishment Process

The miniload system supplies a unit sorter, which sorts the SKU ordered by the stores into shipping cartons. Any source cartons that still contain products are returned into a temporary storage buffer based on shuttles that are effectively capable of handling the opened cartons.

Easy and Accurate Shipping

Shipping cartons are conveyed to the correct dock door and automatically loaded onto trucks, improving the efficiency and accuracy of the shipping process.

About Gap Inc.

Founded in 1969, Gap Inc. is a leading global retailer offering apparel, accessories, and personal care products for men, women, and children. The Gap brands include Gap, Banana Republic, Old Navy, and Athleta. Gap operates in 90 countries worldwide, with over 3,345 company-operated stores, 574 franchise stores, and e-commerce websites.

Optimize Your Material Handling

TGW Logistics is your partner in achieving new levels of efficiency and performance with automated logistics solutions. Ready to hit your next milestone? 

Learn how we can transform your operations.

Contact us today

Raffaele Destro, Vice President Business Development Fashion | TGW Logistics Raffaele Destro, Vice President Business Development Fashion | TGW Logistics

Raffaele Destro

Vice President Market Development

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TGW Logistics è un'impresa appartenente a una fondazione austriaca, leader globale nella logistica e nell'automazione dei magazzini. Con più di 50 anni di esperienza nell’integrazione dei sistemi, offriamo servizi completi: dalla progettazione di centri di distribuzione che utilizzano meccatronica, robotica e soluzioni software avanzate fino alla manutenzione completa e la loro successiva implementazione.

Con oltre 4.600 dipendenti in Europa, Asia e Nord America, mettiamo a disposizione un intreccio di competenze, innovazione e dedizione al cliente per aiutare le aziende a crescere. Con TGW Logistics è possibile elevare la logistica del vostro magazzino a un livello più competitivo.