Some critics say C-TPAT is too lax. Others complain that its requirements are so vague as to be nearly useless. Yet others revile its standards as too stringent and unnecessary. Who's to be believed?
Barry Brandman is president of Danbee Investigations, a Midland Park, N.J., company that provides investigative, loss prevention and security consulting services to many of the top names in the logistics industry. He has been a guest speaker for the Department of Homeland Security, CSCMP, and WERC, and is the author of Security Best Practices: Protecting Your Distribution Center From Inventory Theft, Fraud, Substance Abuse, Cybercrime and Terrorism. You can reach him via e-mail at
or (201) 652-5500.
When it comes to the government security initiative known as C-TPAT, everyone's a critic. Some say it's too lax, charging that thousands of companies have obtained security clearance based on nothing more than their word. Others complain that its requirements are so vague as to be nearly useless. Yet others revile its standards as too stringent and unnecessary. Who's to be believed?
To understand the problem, you need to know a little about the program's background. The Customs-Trade Partnership Against Terrorism (C-TPAT) was conceived in the wake of the catastrophic events of 9/11, when Americans woke up to the fact that we have enemies out there with not only the inclination, but also the lethal capability to exploit weaknesses in domestic security. As U.S. officials scrambled to plug holes in national security in the days following the attacks, they quickly homed in on the commercial supply chain as an area of vulnerability.
U.S. businesses bring approximately 20 million trailers, railcars, air containers and ocean containers into the country each year, each one a target for terrorists bent on smuggling in material that is radioactive, explosive or biologically hazardous.
Right now, the Bureau of Customs and Border Protection (CBP) inspects less than 3 percent of those 20 million inbound shipments. And although there have been calls from Congress to step up inspections, anyone with even a passing familiarity with global supply chains understands the futility of that effort. No matter how much equipment or how many people were allocated to the project, it would be physically impossible to inspect every one of those boxes without choking off commerce. For an idea of the economic impact of widespread delays, you need look no further than the 2002 West Coast port labor dispute. While labor and management wrangled, ocean liners stacked up in the Pacific for as far as the eye could see, weighted down with goods that couldn't be offloaded. American companies, including distributors, logistics service providers, and retailers, felt the financial sting to the
tune of $2 billion a day.
Unable to police the global supply chain on its own, CBP came up with an alternative plan: get U.S. companies to shoulder some of the burden. Customs could significantly increase the effectiveness of the small percentage of inspections taking place if it could focus its resources on the high-risk shipments. CBP has no clout over foreign companies, clearly one of the most vulnerable links in the global supply chain. But U.S. importers have plenty of leverage with their suppliers. If those U.S. importers would commit to upgrading their supply chain security programs and persuading their overseas business partners to do the same, Customs would reward them by reducing their risk of being targeted for inspections. We know that program as C-TPAT.
C-TPAT comes under fire
In its nearly four years of existence, C-TPAT has drawn some flak. Some, for example, have voiced concerns about what they see as inadequate enforcement, charging that certification has been awarded to thousands of companies based solely on the submission of their security Profile Report.
That's a legitimate concern. However, it's also necessary to be pragmatic. After 9/11, the agency was faced with the need to act swiftly. Had Customs waited until it could recruit and fully train hundreds of additional inspectors and procure all the high-tech screening equipment it would need, the C-TPAT program would probably have been delayed 18 to 24 months. In my opinion, that delay would have posed a significantly greater risk than allowing companies to receive certification without being validated.
To be sure, there may have been importers, manufacturers and carriers who were guilty of misrepresentation and neglect. But I believe that a larger percentage of companies applying for C-TPAT certification were serious about identifying their deficiencies, developing and implementing improved safeguards, training their personnel to recognize security threats, and communicating the need to upgrade supply chain safeguards to their overseas suppliers and vendors. As a result, this enormous project got under way sooner rather than two years later.
Another criticism leveled at C-TPAT is that security standards communicated by CBP haven't been detailed or consistent. While it's true that many of the recommended safeguards appear to be generic, security experts understood that it simply wasn't possible to produce a "one size fits all" standard when dealing with thousands of businesses of various types and sizes, all with different logistics and operating practices.
My company is frequently asked to assess corporate supply chains and help companies develop programs compliant with C-TPAT standards. Over the years, we've learned that even companies in the same field and of similar size require customized security solutions rather than broad boilerplate fixes, which tend to be both superficial and ineffective.
Nonetheless, CBP responded to its critics, introducing new and stiffer standards for C-TPAT certification on March 25. Companies seeking C-TPAT certification will need to meet or exceed the new security criteria, which cover areas like container integrity, personnel background checks and IT security. Companies that have already obtained certification have been allowed to bring their operations into compliance in phases.
Still, it appears that CBP can't win. The same parties that had clamored for clearer, better-defined standards jumped all over the new C-TPAT standards, branding them as extreme and unnecessary. I would disagree. Although I may not concur with the requirements on every point, I still think it's necessary to take a broader view of what the C-TPAT program is designed to accomplish as well as the formidable obstacles that must be faced each day.
To those who protest that the new standards are too stringent, I'd like to point out that shipments from C-TPAT certified companies are precisely the shipments most likely to be targeted by terrorist cells. It's no secret that shipments to certified companies stand a much lower than average chance of being opened by CBP inspectors. For that reason, it's imperative that certified companies follow the very best security practices, support their practices with state-of-the-art technology, and diligently check and test their procedures on a regular basis. Anything less creates vulnerabilities.
Making progress
For all the criticism, the good news is that CBP, through programs like C-TPAT and the Container Security Initiative, has made considerable progress, in a relatively short period of time, securing America's borders. Many of America's largest importers have embraced the C-TPAT program and strengthened their supply chain security. Not only has this reduced their exposure to smuggling and cargo theft (itself a multi-billion dollar problem annually), but most C-TPAT-certified companies have also reaped significant financial benefits. To begin with, their risk of shipment delays caused by security inspections has dropped drastically. In addition, their participation in C-TPAT makes them eligible for expedited clearance via Customs' FAST (Free and Secure Trade) program at the Mexican and Canadian borders, and has given them added leverage in negotiating insurance premiums.
Despite its imperfections, I support the concept of C-TPAT. And I'm convinced others will embrace it as well. Consider this: Despite all the complaints, no company that I'm aware of has voluntarily given up its C-TPAT certification. And other countries are now developing security programs for their inbound supply chains that are modeled on America's C-TPAT program.
I certainly don't see C-TPAT going away. To the contrary, I expect that C-TPAT, much like ISO certification, will become a widely recognized standard in the international business community and a reflection of a company's commitment to operational excellence.
Editor's note: This is the first of two parts. Next month's SecurityBrief column will discuss best practices and strategies for obtaining—and keeping—C-TPAT certification.
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]."
First, 54% of retailers are looking for ways to increase their financial recovery from returns. That’s because the cost to return a purchase averages 27% of the purchase price, which erases as much as 50% of the sales margin. But consumers have their own interests in mind: 76% of shoppers admit they’ve embellished or exaggerated the return reason to avoid a fee, a 39% increase from 2023 to 204.
Second, return experiences matter to consumers. A whopping 80% of shoppers stopped shopping at a retailer because of changes to the return policy—a 34% increase YoY.
Third, returns fraud and abuse is top-of-mind-for retailers, with wardrobing rising 38% in 2024. In fact, over two thirds (69%) of shoppers admit to wardrobing, which is the practice of buying an item for a specific reason or event and returning it after use. Shoppers also practice bracketing, or purchasing an item in a variety of colors or sizes and then returning all the unwanted options.
Fourth, returns come with a steep cost in terms of sustainability, with returns amounting to 8.4 billion pounds of landfill waste in 2023 alone.
“As returns have become an integral part of the shopper experience, retailers must balance meeting sky-high expectations with rising costs, environmental impact, and fraudulent behaviors,” Amena Ali, CEO of Optoro, said in the firm’s “2024 Returns Unwrapped” report. “By understanding shoppers’ behaviors and preferences around returns, retailers can create returns experiences that embrace their needs while driving deeper loyalty and protecting their bottom line.”
Facing an evolving supply chain landscape in 2025, companies are being forced to rethink their distribution strategies to cope with challenges like rising cost pressures, persistent labor shortages, and the complexities of managing SKU proliferation.
1. Optimize labor productivity and costs. Forward-thinking businesses are leveraging technology to get more done with fewer resources through approaches like slotting optimization, automation and robotics, and inventory visibility.
2. Maximize capacity with smart solutions. With e-commerce volumes rising, facilities need to handle more SKUs and orders without expanding their physical footprint. That can be achieved through high-density storage and dynamic throughput.
3. Streamline returns management. Returns are a growing challenge, thanks to the continued growth of e-commerce and the consumer practice of bracketing. Businesses can handle that with smarter reverse logistics processes like automated returns processing and reverse logistics visibility.
4. Accelerate order fulfillment with robotics. Robotic solutions are transforming the way orders are fulfilled, helping businesses meet customer expectations faster and more accurately than ever before by using autonomous mobile robots (AMRs and robotic picking.
5. Enhance end-of-line packaging. The final step in the supply chain is often the most visible to customers. So optimizing packaging processes can reduce costs, improve efficiency, and support sustainability goals through automated packaging systems and sustainability initiatives.
Keith Moore is CEO of AutoScheduler.AI, a warehouse resource planning and optimization platform that integrates with a customer's warehouse management system to orchestrate and optimize all activities at the site. Prior to venturing into the supply chain business, Moore was a director of product management at software startup SparkCognition. He is a graduate of the University of Tennessee, where he earned a Bachelor of Science degree in mechanical engineering.
Q: Autoscheduler provides tools for warehouse orchestration—a term some readers may not be familiar with. Could you explain what warehouse orchestration means?
A: Warehouse orchestration tools are software control layers that synthesize data from existing systems to eliminate costly delays, streamline inefficient workflows, and [prevent the waste of] resources in distribution operations. These platforms empower warehouses to optimize operations, enhance productivity, and improve order accuracy by dynamically prioritizing work continuously to ensure that the operation is always running optimally. This leads to faster trailer turn times, reduced costs, and a network that runs like clockwork, even during fluctuating demands.
Q: How is orchestration different from a typical warehouse management system?
A: A warehouse management system (WMS) focuses on tracking inventory and managing warehouse operations. Warehouse orchestration goes a step further by integrating and optimizing all aspects of warehouse activities in a capacity-constrained way. Orchestration provides a dynamic, real-time layer that coordinates various systems and processes, enabling more agile and responsive operations. It enhances decision-making by considering multiple variables and constraints.
Q: How does warehouse orchestration help facilities make their workers more productive?
A: Two ways to make labor in a warehouse more productive are to work harder and to work smarter. For teams that want to work harder, most companies use a labor management system to track individual performances against an expected standard. Warehouse orchestration technology focuses on the other side of the coin, helping warehouses "work smarter."
Warehouse orchestration technology optimizes labor by providing real-time insights into workload demands and resource availability based on actual fluctuating constraints around the building. It enables dynamic task assignments based on current priorities and worker skills, ensuring that labor is allocated where it's needed most, even accounting for equipment availability, flow constraints, and overall work speed. This approach reduces idle time, balances workloads, and enhances employee productivity.
Q: How can visibility improve operations?
A: Due to the software ecosystem in place today, most distribution operations are highly reactive environments where there is always a "hair on fire" problem that needs to be solved. By leveraging orchestration technologies, this problem is mitigated because you're providing the site with added visibility into the past, present, and future state of the operation. This opens up a vast number of doors for distribution leadership. They go from learning about a problem after it's happened to gaining the ability to inform customers and transportation teams about potential service issues that are 24 hours away.