The Challenge: Inaccurate Labels & Inefficient Operations
Luxottica, one of the world's largest eyewear companies, was experiencing significant operational issues across their distribution facility:
- 140,000+ location labels were inaccurate or deteriorating, causing mispicks and fulfillment delays
- Packing stations were inefficiently designed, leading to wasted motion and reduced throughput
- Packaging materials were outdated, non-biodegradable and oversized, increasing both cost and environmental impact
These compounding issues were driving up labor costs, damaging customer satisfaction, and creating compliance concerns.
The CIS Solution: A Three-Pronged Approach
CIS deployed a comprehensive solution addressing all three problem areas simultaneously:
1. Warehouse Location Label Overhaul
| Component | Details |
|---|---|
| Scope | 140,000+ location labels replaced across the entire facility |
| Timeline | Completed in under 2 weeks |
| Method | Full audit, removal of outdated labels, and installation of new durable labels |
| Result | Restored pick accuracy and eliminated label-related mispicks |
2. Lean Packing Station Redesign
CIS redesigned Luxottica's packing stations using Lean manufacturing principles:
- Ergonomic layout, reduced unnecessary reaching and bending
- Standardized workflows, consistent station setup across all lines
- Material placement optimization, supplies positioned for minimal motion waste
- Visual management cues, color-coded zones and clear signage
The redesigned stations improved packer throughput and reduced fatigue-related errors.
3. Biodegradable LDPE Packaging Conversion
CIS transitioned Luxottica from conventional packaging to biodegradable LDPE (Low-Density Polyethylene):
- 8% material reduction through right-sizing packaging to product dimensions
- Biodegradable material, meets sustainability targets without sacrificing protection
- Cost savings, less material per package and reduced waste disposal costs
The Results
The combined impact across all three initiatives delivered measurable ROI:
Key Stats
| Metric | Result |
|---|---|
| 💰 Annual Savings | $34,000+ across labeling, packing, and packaging improvements |
| 🏷️ Labels Fixed | 140,000+ locations re-labeled in under 2 weeks |
| 📦 Material Reduction | 8% through biodegradable LDPE right-sizing |
Additional Benefits
- Improved pick accuracy, elimination of label-related mispicks
- Faster packing times, Lean station design reduced wasted motion
- Sustainability gains, biodegradable packaging supports environmental goals
- Employee satisfaction, ergonomic stations reduced physical strain
Why It Worked
CIS's holistic approach addressed the interconnected root causes rather than treating symptoms individually:
- Accurate labels ensured the right products reached packing stations
- Lean stations processed those products faster with fewer errors
- Right-sized packaging reduced material costs and environmental impact
"CIS didn't just fix our labels, they transformed our entire fulfillment workflow.", Luxottica Distribution Operations
Download the Full Case Study
📄 Download the Luxottica Case Study (PDF)
Explore Our Solutions
Looking for a similar transformation in your facility? CIS provides end-to-end solutions:
- Warehouse Labeling - Location labels, rack labels, and identification systems
- Industrial Labels - Custom labels for any application
- Packaging Materials - Sustainable packaging solutions
- Material Handling - Lean workstation design and optimization