John Johnson joined the DC Velocity team in March 2004. A veteran business journalist, John has over a dozen years of experience covering the supply chain field, including time as chief editor of Warehousing Management. In addition, he has covered the venture capital community and previously was a sports reporter covering professional and collegiate sports in the Boston area. John served as senior editor and chief editor of DC Velocity until April 2008.
Is your company prepared for a flu pandemic? If you work in the food industry, you probably answered yes to that question. But if you work for an energy company, industrial manufacturer or retailer, chances are you said no. A recent study by AMR Research found wide variations among industries when it comes to disaster preparedness.
If your company hasn't made much headway in crisis planning, you're not alone. The AMR study found that nearly 60 percent of enterprises surveyed had yet to adopt supply chain risk management policies. And even among those who had begun drafting policies, many appear to be still in the evaluation stage.
A study conducted by DC VELOCITY earlier this year also found a distinct lack of preparedness among survey respondents. Some 43 percent said they did not have general business continuity plans. Of those who had continuity plans, a staggering 83 percent had not yet addressed the possibility of a flu pandemic. Nor did they intend to. Nearly 75 percent of those who hadn't yet considered the impact of a flu outbreak admitted they had no immediate plans to do so. (See accompanying graphs.)
Not surprisingly, the companies most likely to find themselves on the frontlines in an emergency had made the greatest progress with their planning. "Certain sectors are more in tune to this than others," says AMR Research analyst Mark Hillman. Transportation businesses and chemical manufacturers tend to be ahead of the pack, he says. Food suppliers are at the top of the list as well. Take Hickory, N.C.-based food distributor Alex Lee Inc., for example. Alex Lee, which believes it has a responsibility to prevent disruption to the nation's food supply, has not only drafted a comprehensive pandemic plan, but is also well along in its efforts to implement that plan.
As for which businesses lag behind, the AMR report singles out automotive manufacturers, retailers and even some pharmaceutical concerns. The aerospace and defense industries are also at risk, AMR says, because of their tendency to forge sole-source agreements with specialized suppliers. "They are sensitive to the issue," says Hillman, "but the average company doesn't understand how much risk there is in their supply chain. The supply networks that will survive in the event of a pandemic or other major event are the ones that are the most prepared."
There are companies you'd expect to find on the forefront of disaster planning—food suppliers, say, or power and pharmaceutical companies.But chances are, semiconductor manufacturers wouldn't be high on your list.
Yet chipmaker Intel has emerged in recent years as one of the front runners in disaster preparedness. Over the past decade or so, the technology giant has devoted untold resources to business continuity planning, meticulously drafting provisions for dealing with everything from civil unrest, labor strikes and hurricanes to terrorist attacks and malicious computer viruses.
But for all the threats of earthquakes and tsunamis, the buzz at the company's Santa Clara, Calif., headquarters during the past 12 months has centered on a microscopic virus—the H5N1 virus, to be precise. H5N1, a particularly virulent strain of avian flu, has spread through Asia, Africa and Europe in the past decade. Public health officials fear that the virus will someday mutate to a form transmissible by humans, triggering a global flu pandemic.
In response to mounting warnings of a flu pandemic, Intel has formed an executive management team to study the potential impact of an avian flu outbreak on its business. Over the past year, it has pulled thousands of staffers into pandemic meetings and drills. It has enhanced its information technology infrastructure so that nearly half of its 105,000 employees will be able to work from home if necessary. It has arranged to stock enough food at each of its major facilities to feed one-third of its employees for three days. It has even stockpiled hand sanitizer, face masks and respirators.
Why would Intel go to such lengths to prepare for what many consider an unlikely event? A pandemic may represent a low-probability risk, but its potential consequences are staggering, answers Jim Wick, Intel's environmental health and safety manager for the Americas. By putting measures in place now, he says, the company boosts its chances of bouncing back if a pandemic does erupt. "If indeed a phase six pandemic [the worst possible scenario] occurs, the companies that have protected their people and their assets best will be in a position to recover quickest and become a contributing part of their community again."
Intel's interest in pandemic planning is more than a matter of protecting its profits, says Wick. "There is a business component to this," he concedes, "but there is also a moral and ethical component that outweighs that." Unlike many corporations, he notes, Intel is not stockpiling Tamiflu, the only medication available for treating avian flu (if administered early enough). Many Fortune 500 companies have stockpiled the drug to use for key employees, a controversial move that has depleted supplies of the drug. Intel has instead chosen to forge close relationships with public health agencies in hopes of getting a fast response to its requests should the need arise.
"We will not undermine a national strategy for the allocation
of a scarce resource," says Wick. "We think we have [executives] who ought to have access to [Tamiflu], but we
are not going to horde it at the expense of hospital emergency rooms."
Test drive
Intel's exhaustive disaster planning efforts might strike some as overkill, but it's hard to argue with the results. In the past four years alone, Intel has successfully implemented various provisions of its business continuity plan more than 200 times, as it responded to crises ranging from civil unrest to union strikes and storms like Katrina worldwide.
"A lot of those incidents occurred at the local site level and were not a big deal. But think about events like Katrina that have occurred over the last year or so and you can see the kind of impact it might have in your logistics transportation activities," says Tony Sundermeier, Intel's customer logistics manager for the Americas. "The good news is we are not sole-source suppliers for our transportation services, so if something happens to one supplier, we can react."
Intel will not discuss its distribution network or its specific plans for ensuring product availability during a flu pandemic. However, it's clear from executives' statements that Intel plans to pull its suppliers into the effort. Sundermeier, for example, reports that Intel has already requested that its suppliers take specified steps to prepare for a flu pandemic.
"That's one of the key considerations transportation- wise," he says. "For a logistics professional, it's a daily part of doing business. About 95 percent of the time, everything runs well. It's how you manage that other 5 percent that differentiates you from the others. You need to build in a lot of redundancies in order to be able to change on a dime."
Money well spent
Despite the potentially catastrophic effects of a pandemic, it's often tough to convince management to invest time and money to plan for something like a flu outbreak, which could be six months—or six years—away. That's especially true of public companies, where management may be more concerned about the next quarter's financial results than in preparing for something as uncertain as a pandemic. And if rival companies aren't making similar investments, those managers will be all the more reluctant to spend money on pandemic preparedness for fear their earnings will look bad by comparison.
But the folks at Intel say it's money well spent. "It's like buying insurance," Steve Lund, Intel's director of security and head of its crisis response team, told a recent forum held at the Massachusetts Institute of Technology's Center for Transportation & Logistics. "Hopefully, you never have to cash it in. Yes, we are considered a cost [on the balance sheet]. And not all companies are willing to invest that money. But we provide a service that allows you to be much more profitable in the future [should a crisis occur]."
The New York-based industrial artificial intelligence (AI) provider Augury has raised $75 million for its process optimization tools for manufacturers, in a deal that values the company at more than $1 billion, the firm said today.
According to Augury, its goal is deliver a new generation of AI solutions that provide the accuracy and reliability manufacturers need to make AI a trusted partner in every phase of the manufacturing process.
The “series F” venture capital round was led by Lightrock, with participation from several of Augury’s existing investors; Insight Partners, Eclipse, and Qumra Capital as well as Schneider Electric Ventures and Qualcomm Ventures. In addition to securing the new funding, Augury also said it has added Elan Greenberg as Chief Operating Officer.
“Augury is at the forefront of digitalizing equipment maintenance with AI-driven solutions that enhance cost efficiency, sustainability performance, and energy savings,” Ashish (Ash) Puri, Partner at Lightrock, said in a release. “Their predictive maintenance technology, boasting 99.9% failure detection accuracy and a 5-20x ROI when deployed at scale, significantly reduces downtime and energy consumption for its blue-chip clients globally, offering a compelling value proposition.”
The money supports the firm’s approach of "Hybrid Autonomous Mobile Robotics (Hybrid AMRs)," which integrate the intelligence of "Autonomous Mobile Robots (AMRs)" with the precision and structure of "Automated Guided Vehicles (AGVs)."
According to Anscer, it supports the acceleration to Industry 4.0 by ensuring that its autonomous solutions seamlessly integrate with customers’ existing infrastructures to help transform material handling and warehouse automation.
Leading the new U.S. office will be Mark Messina, who was named this week as Anscer’s Managing Director & CEO, Americas. He has been tasked with leading the firm’s expansion by bringing its automation solutions to industries such as manufacturing, logistics, retail, food & beverage, and third-party logistics (3PL).
Supply chains continue to deal with a growing volume of returns following the holiday peak season, and 2024 was no exception. Recent survey data from product information management technology company Akeneo showed that 65% of shoppers made holiday returns this year, with most reporting that their experience played a large role in their reason for doing so.
The survey—which included information from more than 1,000 U.S. consumers gathered in January—provides insight into the main reasons consumers return products, generational differences in return and online shopping behaviors, and the steadily growing influence that sustainability has on consumers.
Among the results, 62% of consumers said that having more accurate product information upfront would reduce their likelihood of making a return, and 59% said they had made a return specifically because the online product description was misleading or inaccurate.
And when it comes to making those returns, 65% of respondents said they would prefer to return in-store, if possible, followed by 22% who said they prefer to ship products back.
“This indicates that consumers are gravitating toward the most sustainable option by reducing additional shipping,” the survey authors said in a statement announcing the findings, adding that 68% of respondents said they are aware of the environmental impact of returns, and 39% said the environmental impact factors into their decision to make a return or exchange.
The authors also said that investing in the product experience and providing reliable product data can help brands reduce returns, increase loyalty, and provide the best customer experience possible alongside profitability.
When asked what products they return the most, 60% of respondents said clothing items. Sizing issues were the number one reason for those returns (58%) followed by conflicting or lack of customer reviews (35%). In addition, 34% cited misleading product images and 29% pointed to inaccurate product information online as reasons for returning items.
More than 60% of respondents said that having more reliable information would reduce the likelihood of making a return.
“Whether customers are shopping directly from a brand website or on the hundreds of e-commerce marketplaces available today [such as Amazon, Walmart, etc.] the product experience must remain consistent, complete and accurate to instill brand trust and loyalty,” the authors said.
When you get the chance to automate your distribution center, take it.
That's exactly what leaders at interior design house
Thibaut Design did when they relocated operations from two New Jersey distribution centers (DCs) into a single facility in Charlotte, North Carolina, in 2019. Moving to an "empty shell of a building," as Thibaut's Michael Fechter describes it, was the perfect time to switch from a manual picking system to an automated one—in this case, one that would be driven by voice-directed technology.
"We were 100% paper-based picking in New Jersey," Fechter, the company's vice president of distribution and technology, explained in a
case study published by Voxware last year. "We knew there was a need for automation, and when we moved to Charlotte, we wanted to implement that technology."
Fechter cites Voxware's promise of simple and easy integration, configuration, use, and training as some of the key reasons Thibaut's leaders chose the system. Since implementing the voice technology, the company has streamlined its fulfillment process and can onboard and cross-train warehouse employees in a fraction of the time it used to take back in New Jersey.
And the results speak for themselves.
"We've seen incredible gains [from a] productivity standpoint," Fechter reports. "A 50% increase from pre-implementation to today."
THE NEED FOR SPEED
Thibaut was founded in 1886 and is the oldest operating wallpaper company in the United States, according to Fechter. The company works with a global network of designers, shipping samples of wallpaper and fabrics around the world.
For the design house's warehouse associates, picking, packing, and shipping thousands of samples every day was a cumbersome, labor-intensive process—and one that was prone to inaccuracy. With its paper-based picking system, mispicks were common—Fechter cites a 2% to 5% mispick rate—which necessitated stationing an extra associate at each pack station to check that orders were accurate before they left the facility.
All that has changed since implementing Voxware's Voice Management Suite (VMS) at the Charlotte DC. The system automates the workflow and guides associates through the picking process via a headset, using voice commands. The hands-free, eyes-free solution allows workers to focus on locating and selecting the right item, with no paper-based lists to check or written instructions to follow.
Thibaut also uses the tech provider's analytics tool, VoxPilot, to monitor work progress, check orders, and keep track of incoming work—managers can see what orders are open, what's in process, and what's completed for the day, for example. And it uses VoxTempo, the system's natural language voice recognition (NLVR) solution, to streamline training. The intuitive app whittles training time down to minutes and gets associates up and working fast—and Thibaut hitting minimum productivity targets within hours, according to Fechter.
EXPECTED RESULTS REALIZED
Key benefits of the project include a reduction in mispicks—which have dropped to zero—and the elimination of those extra quality-control measures Thibaut needed in the New Jersey DCs.
"We've gotten to the point where we don't even measure mispicks today—because there are none," Fechter said in the case study. "Having an extra person at a pack station to [check] every order before we pack [it]—that's been eliminated. Not only is the pick right the first time, but [the order] also gets packed and shipped faster than ever before."
The system has increased inventory accuracy as well. According to Fechter, it's now "well over 99.9%."
IT projects can be daunting, especially when the project involves upgrading a warehouse management system (WMS) to support an expansive network of warehousing and logistics facilities. Global third-party logistics service provider (3PL) CJ Logistics experienced this first-hand recently, embarking on a WMS selection process that would both upgrade performance and enhance security for its U.S. business network.
The company was operating on three different platforms across more than 35 warehouse facilities and wanted to pare that down to help standardize operations, optimize costs, and make it easier to scale the business, according to CIO Sean Moore.
Moore and his team started the WMS selection process in late 2023, working with supply chain consulting firm Alpine Supply Chain Solutions to identify challenges, needs, and goals, and then to select and implement the new WMS. Roughly a year later, the 3PL was up and running on a system from Körber Supply Chain—and planning for growth.
SECURING A NEW SOLUTION
Leaders from both companies explain that a robust WMS is crucial for a 3PL's success, as it acts as a centralized platform that allows seamless coordination of activities such as inventory management, order fulfillment, and transportation planning. The right solution allows the company to optimize warehouse operations by automating tasks, managing inventory levels, and ensuring efficient space utilization while helping to boost order processing volumes, reduce errors, and cut operational costs.
CJ Logistics had another key criterion: ensuring data security for its wide and varied array of clients, many of whom rely on the 3PL to fill e-commerce orders for consumers. Those clients wanted assurance that consumers' personally identifying information—including names, addresses, and phone numbers—was protected against cybersecurity breeches when flowing through the 3PL's system. For CJ Logistics, that meant finding a WMS provider whose software was certified to the appropriate security standards.
"That's becoming [an assurance] that our customers want to see," Moore explains, adding that many customers wanted to know that CJ Logistics' systems were SOC 2 compliant, meaning they had met a standard developed by the American Institute of CPAs for protecting sensitive customer data from unauthorized access, security incidents, and other vulnerabilities. "Everybody wants that level of security. So you want to make sure the system is secure … and not susceptible to ransomware.
"It was a critical requirement for us."
That security requirement was a key consideration during all phases of the WMS selection process, according to Michael Wohlwend, managing principal at Alpine Supply Chain Solutions.
"It was in the RFP [request for proposal], then in demo, [and] then once we got to the vendor of choice, we had a deep-dive discovery call to understand what [security] they have in place and their plan moving forward," he explains.
Ultimately, CJ Logistics implemented Körber's Warehouse Advantage, a cloud-based system designed for multiclient operations that supports all of the 3PL's needs, including its security requirements.
GOING LIVE
When it came time to implement the software, Moore and his team chose to start with a brand-new cold chain facility that the 3PL was building in Gainesville, Georgia. The 270,000-square-foot facility opened this past November and immediately went live running on the Körber WMS.
Moore and Wohlwend explain that both the nature of the cold chain business and the greenfield construction made the facility the perfect place to launch the new software: CJ Logistics would be adding customers at a staggered rate, expanding its cold storage presence in the Southeast and capitalizing on the location's proximity to major highways and railways. The facility is also adjacent to the future Northeast Georgia Inland Port, which will provide a direct link to the Port of Savannah.
"We signed a 15-year lease for the building," Moore says. "When you sign a long-term lease … you want your future-state software in place. That was one of the key [reasons] we started there.
"Also, this facility was going to bring on one customer after another at a metered rate. So [there was] some risk reduction as well."
Wohlwend adds: "The facility plus risk reduction plus the new business [element]—all made it a good starting point."
The early benefits of the WMS include ease of use and easy onboarding of clients, according to Moore, who says the plan is to convert additional CJ Logistics facilities to the new system in 2025.
"The software is very easy to use … our employees are saying they really like the user interface and that you can find information very easily," Moore says, touting the partnership with Alpine and Körber as key to making the project a success. "We are on deck to add at least four facilities at a minimum [this year]."