How to implement Garment on Hanger (GOH) operations in a warehouse

Setting up Garment on Hanger (GOH) operations in a warehouse requires a mix of layout planning, equipment selection, process design, staff training, and systems integration. A successful GOH program minimizes damage to apparel, speeds store replenishment, and reduces handling costs — but it must be thoughtfully implemented to balance space, labor, and cost.

Step-by-step implementation roadmap:

1. Define scope and objectives: Start by deciding which SKUs will use GOH. Consider product type (suits, dresses, coats), price tier, and customer expectations. Set KPIs such as hang-to-shelf time, pick accuracy, damage rate, and cost per unit handled.
2. Assess space and flows: GOH requires vertical hanging lanes and unobstructed aisle width for mobile racks. Map incoming, inspection, storage, picking, and outbound staging areas to minimize double-handling. Identify locations for cross-docking if the goal is rapid store fulfillment.
3. Select material handling equipment: Choose the right mix of mobile hanging racks, fixed hanging rails, hanging pallets, and GOH conveyors. Consider collapsible racks for return trips, and ensure racks can be secured for transport. Mobile racks with standard rail spacing reduce hanger tangling and ease counting.
4. Specify hangers, covers, and fixtures: Standardize hanger types (e.g., plastic, wood, or wire) and cover materials. Reusable hangers reduce waste, but make sure type is compatible with automated sorters or racking. Use protective polybags or garment covers to prevent dust and moisture damage during storage and transport.
5. Configure warehouse systems: Update WMS to support GOH inventory units (SKU-on-hanger, rack IDs). Track movement at the rack or hanger level depending on desired granularity. Integrate barcode or RFID tagging so picks, transfers, and shipments are scanned for visibility. Configure routing logic to support cross-dock vs. putaway workflows.
6. Design receiving and inspection procedures: Create a GOH-specific receiving bay where garments can be inspected while still on hangers. Use dedicated lanes for quality control and label application so items are ready for storage or direct shipment.
7. Develop picking and packing workflows: Decide whether to pick by hanger, by rack, or by whole-rail. For B2B or store replenishment, whole-rail moves minimize handling. For e-commerce, implement pick-to-hanger processes where individual items are removed, bagged, and shipped while maintaining SKU integrity.
8. Plan transport and staging: Racks and hanging pallets must be compatible with truck loading configurations to avoid unnecessary rehangs. Plan staging areas for outbound racks and secure them during transit to prevent sliding and garment damage.
9. Train staff: Equip teams with safe handling techniques for hanging garments, loading/unloading racks, and using conveyors. Teach inspection protocols and how to tag or rework items requiring repair.
10. Test and iterate: Run pilot flows with a small selection of SKUs and refine spacing, labeling, and equipment choices. Measure KPIs and adjust processes to reduce damage and improve throughput.

Technology and automation options:

• WMS configuration: Add GOH-specific units of measure and storage locations. Use lot and serial tracking if garments require traceability.
• RFID tagging: Fastens inventory visibility; individual hangers or garment loops can carry RFID tags enabling rapid counts and loss prevention.
• GOH conveyors and sorters: Speed inspection and labeling while garments remain hung and minimize manual touching.
• Label printers and applicators: Automated label application to hanger clips or garment loops speeds receiving and reduces mistakes.

Operational tips and best practices:

• Standardize hanger and rail spacing to avoid tangling and to maintain consistent package dimensions for transport.
• Group assortments by store or shipping lane at the packing stage to streamline cross-dock flows.
• Use reusable rack systems and return logistics to lower long-term costs and environmental impact.
• Implement clear damage-handling SOPs so any garment needing repair or rework is routed immediately to a rework station.
• Incorporate safety measures: racks need locking mechanisms and clear signage to prevent tipping and to guide forklift operations.

Measuring success:

Track metrics like units handled per hour, average hang-to-ship time, percentage of garments requiring rework, damage per thousand units, and space utilization. These KPIs show where to optimize layout, staffing, or equipment investments.

Example implementation scenario:

A mid-size retailer pilots GOH for outerwear. They allocate a receiving lane with hanging rails where shipments are inspected and tagged. Racks are moved to a staging area for cross-docking to store-specific pallets. The WMS tracks rack IDs and links them to store orders; upon arrival, store staff roll racks directly to fixtures. Within weeks, store-ready time drops significantly and markdowns due to mishandling fall.

In short, implementing Garment on Hanger (GOH) in a warehouse is a deliberate blend of space planning, equipment choice, process redesign, and system integration. With the right preparation and measures in place, GOH can yield faster store replenishment, better presentation, and lower product rework.