Custom Clothing Crunch – A Case Study

Custom Clothing Crunch - A Case Study

PRODUCTS: Selective Pallet Rack, Bin Shelving, Picking Carts with Bins, Packing Tables
Installation, Project Management
Los Angeles, CA


A well-established online clothing company was in the process of moving warehouses when they sought out REB’s services. The company provides customized apparel and accessories. This unique operation required higher efficiency to be able to keep up with fulfilling customized orders.

The company had a predetermined location but needed expertise on increasing the efficiency of their picking and packing systems.

The desired completion date was right around the corner, requiring REB’s team to work quickly to ensure the project would be completed by the desired date, which was 30 days away.


REB assessed the warehouse space, as well as the company’s current process. It was determined that the company would benefit from the following:

  • An area for bulk/overflow
  • An area for easy access to piece-picking.
  • An efficient method of retrieving products from the piece picking area. This includes the ability to organize each order individually and quickly transport orders to the printing
  • A better-organized space for packing

REB project designers developed a warehouse layout depicting the designated space for each material handling solution.

Bin shelving is used to hold items intended for quick picks. Each bin stores items of the same SKU. When a custom order is placed online, the picker locates the correct bins, places each item in the picking cart, and scans the appropriate SKU. Once this is complete, the order is then brought to the printing area.

Bin Shelving

Selective pallet rack is intended to hold apparel in bulk. This racking allows for various sized boxes to be located throughout the rack, making it an efficient way to store numerous clothing types that may require different sized boxes. The bulk items placed on the selective rack will replenish the picking bins when product runs low. Ladder carts are used to access shelves out of reach.

Selective Pallet Rack

Picking carts equipped with bins were determined to be the best solution for pickers to retrieve products from the piece picking area, organize products by shipment, and transport products over to the printing area. The carts feature 3-levels of slanted shelves to allow for easier placement of products as well as increased visibility into each bin.

Packing tables are conveniently located near the picking aisles. The tables are standard shelf packing tables. These tables consist of a lower shelf on the bottom, adjustable legs for height, and punch outlets which allow a power cord to run through.

Picking Carts With Bins


The project was completed within the 30-day requested time frame. The company has increased their efficiency, resulting in higher pick and ship rates.

How did REB meet the 30-day deadline? Due to our extensive relationships with manufacturers across the US, REB was able to identify separate manufacturers for the racking, shelving, picking carts and tables that could supply the products via their quick ship programs. This allowed for the procurement of the products within 72 hours.

Let's Connect!

REB has been providing material handling systems to the warehousing and distribution industry since 1962. We understand that not all products fit the typical racking options. Our team of project designers specializes in evaluating SKUs and designing a storage system based on them, giving you a system that uses every available inch of available storage space.

We’d appreciate the opportunity to help you further, whether that be more information or a quote. Fill in the contact form on this page or call us at (800) 252-5955 to get in touch with a REB representative.

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Brian Dubin

All Products Automotive, Inc.

“We have been a customer for over 15 years. REB offers a good selection of products at great prices. They are an excellent source of materials along with suggestions and information on a variety of storage issues."

Bruce Moulton

Harrington Industrial Plastics

“REB is by far my favorite vendor, the customer service and dedication to making sure every order is complete and on time. Fantastic communication, and an absolute pleasure to work with.”

Gary Rothschild

Epko Industries

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Cabernet Corporation

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Pacific Storage Company

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Tom Beckermann

Felling Trailers Inc.

“REB Storage Systems provides a high quality product with the best customer service in the industry, no matter the volume of products we buy.”

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