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.
Maybe it just sounds too good to be true—something like those e-mails claiming Microsoft will pay you $100 just for forwarding the message to your network of friends. Despite well-documented gains by Wal-Mart and other early adopters of RFID technology, U.S. retailers have been slow to get into the game. With the exception of a few giant chains like Target, Wal-Mart and Best Buy, the byword in the retail world has been watch and wait.
"Outside of those few companies, there isn't a lot of movement," says David Hogan, chief information officer for the National Retail Federation. Hogan says he hasn't seen any signs that the rush will be getting under way anytime soon. "The word we keep hearing is '[We'll] take a look at it in 2010 and see if the price is down and the reliability is up.'"
Retailers themselves offer a variety of reasons for their hesitation. Some feel they have little to gain from RFID because their operations are already running at maximum efficiency. Others say they're worried about getting caught in the crossfire in the battle over privacy. But Hogan thinks it's more a matter of simple economics. Many retailers are reluctant to invest in RFID, he says, because they're dubious about the prospects for payback.
Billions in benefits
A new study may chase away those doubts. A report released late last year suggests that RFID's economic benefits may be far higher than previously estimated. Even at today's relatively low adoption levels (9 percent of retail sales at the pallet level and 2 percent of sales at the item level), the study says, retailers currently derive an astonishing $12.05 billion in benefits from RFID applications.
The gains, according to the researchers, are coming from reductions in labor costs, decreases in "shrinkage" from theft, and reductions in inventory write-offs as well as better product availability and faster time to market. And the savings promise to be ongoing. If, as predicted, adoption rates reach 45 percent of sales at the pallet level and 20 percent at the item level, RFID could be worth a whopping $68.55 billion in benefits to retailers by 2011.
Even the RFID chip-maker that commissioned the study found the results to be an eye-opener. "We were quite [surprised] by the sheer [size of the] returns the study shows," says Jan-Willem Reynaerts, general manager for the RFID market sector team at NXP Semiconductors, which was spun off from Philips last year. The company, which is based in Eindhoven, the Netherlands, commissioned the study, which was conducted by researchers from the University of Texas at Austin.
The study also calls into question the claim that retailers aren't seeing much of a payback on their RFID investments. Anitesh Barua, one of the study's authors, puts the cumulative retail sector spending on RFID technologies (from 2003 through 2006) at $2.37 billion. Based on that, the $12.05 billion payback figure represents a nearly fivefold aggregate return.
No more black bananas?
There's more to the RFID story than dazzling returns, analysts say. RFID also shows great promise for solving some long-standing business problems. "RFID is a very significant business opportunity that is there to be understood and embraced, and that's what separates the companies that get it from those that don't," says Marshall Kay, North American practice leader for RFID at Kurt Salmon Associates. "Wal-Mart, Best Buy and [German retailer] Metro clearly get it and understand exactly what RFID has the ability to do. They are investing time and money to determine how best it can help them."
One way in which RFID may help retailers is by cutting down on waste and spoilage. That would be an economic boon to both the grocery and the pharmaceutical sectors. Suppliers of perishable goods—from bananas to oncology drugs—typically experience $35 billion worth of waste each year, according to the RFID Research Center at the University of Arkansas.
Much of the damage occurs while products are in transit. "Loss and damage of perishable goods during storage and transportation is a substantial global issue," says Doug Standley, co-leader of Deloitte Consulting's wireless and sensor solutions group, "with some industry sources estimating that losses of up to 33 percent on perishable freight are common. The good news is that emerging technologies are now ready to address this issue."
RFID is one of those emerging technologies. In tests recently conducted by Deloitte and the RFID Research Center in collaboration with Chiquita Brands, researchers successfully used a combination of wireless, sensor, RFID and Internet technologies to monitor temperatures of perishables while in transit. Among other findings, the tests revealed that temperatures varied widely within a single refrigerated trailer, fluctuating as much as 35 percent from pallet to pallet. By using RFID tags with temperature sensors, the researchers were able to collect a temperature history for each pallet. That type of monitoring system would make it possible for retailers to identify which pallets have been exposed to the highest temperatures (and thus have the shortest expected shelf life), so they could unload and use them first.
"The preliminary data from the experiment are already beginning to provide insight into a real-world environment that until now had been prohibitively expensive to track," says Bill Hardgrave, founder and director of the RFID Research Center. "Overall, this project—even at this early stage—is rapidly bringing into focus the vision of a truly intelligent cold chain."
Let the revolution begin!
The cold chain benefits notwithstanding, most analysts say RFID's full potential has yet to be unleashed. That won't happen until item-level tagging becomes common practice among retailers. Though that day may still be some years off, say Barua and Reynaerts, it will irrevocably change the industry when it arrives. They believe the combined benefits of item-level tagging to retailers could exceed $150 billion upon full deployment.
In the meantime, Hardgrave says interest in item-level tagging is picking up. Some of the retailers that are working with the RFID Research Center have begun moving down that path, he reports, though most of them have barred the center from revealing their identities for competitive reasons.
One retailer known to be pushing ahead with item-level tagging is the UK-based retail chain Marks & Spencer. M&S, whose item-level tagging pilots date back to 2002, plans to extend its apparel-tagging program to 120 stores this spring, concentrating initially on lines of clothing that come in a wide variety of sizes—like men's suits and women's jackets and bras. M&S hopes the tags—which are Gen 2 HF tags applied at the point of manufacture—will improve inventory visibility and help reduce stock-outs.
Japanese retailer Mitsukoshi is said to be expanding its item-level tagging program as well. According to published reports, the retailer credits item-level RFID tags with helping boost sales by 13 percent in the women's shoe department at its flagship store in Tokyo. Mitsukoshi is currently using the technology at seven stores across Japan and may introduce it at its U.S. stores in Orlando, Fla., and Honolulu later this year.
Does that mean the RFID revolution is finally under way? Bill Colleran, CEO of tag and reader maker Impinj, thinks it is. "In a few short years, every object in our world will have an electronically accessible number on it," Colleran told attendees at an educational forum hosted by AIM Global in November. "In the near future, all manufacturers and retailers worldwide will adopt RFID, and it will change our lives in profound ways."
The Boston-based enterprise software vendor Board has acquired the California company Prevedere, a provider of predictive planning technology, saying the move will integrate internal performance metrics with external economic intelligence.
According to Board, the combined technologies will integrate millions of external data points—ranging from macroeconomic indicators to AI-driven predictive models—to help companies build predictive models for critical planning needs, cutting costs by reducing inventory excess and optimizing logistics in response to global trade dynamics.
That is particularly valuable in today’s rapidly changing markets, where companies face evolving customer preferences and economic shifts, the company said. “Our customers spend significant time analyzing internal data but often lack visibility into how external factors might impact their planning,” Jeff Casale, CEO of Board, said in a release. “By integrating Prevedere, we eliminate those blind spots, equipping executives with a complete view of their operating environment. This empowers them to respond dynamically to market changes and make informed decisions that drive competitive advantage.”
Material handling automation provider Vecna Robotics today named Karl Iagnemma as its new CEO and announced $14.5 million in additional funding from existing investors, the Waltham, Massachusetts firm said.
The fresh funding is earmarked to accelerate technology and product enhancements to address the automation needs of operators in automotive, general manufacturing, and high-volume warehousing.
Iagnemma comes to the company after roles as an MIT researcher and inventor, and with leadership titles including co-founder and CEO of autonomous vehicle technology company nuTonomy. The tier 1 supplier Aptiv acquired Aptiv in 2017 for $450 million, and named Iagnemma as founding CEO of Motional, its $4 billion robotaxi joint venture with automaker Hyundai Motor Group.
“Automation in logistics today is similar to the current state of robotaxis, in that there is a massive market opportunity but little market penetration,” Iagnemma said in a release. “I join Vecna Robotics at an inflection point in the material handling market, where operators are poised to adopt automation at scale. Vecna is uniquely positioned to shape the market with state-of-the-art technology and products that are easy to purchase, deploy, and operate reliably across many different workflows.”
Third-party logistics (3PL) providers’ share of large real estate leases across the U.S. rose significantly through the third quarter of 2024 compared to the same time last year, as more retailers and wholesalers have been outsourcing their warehouse and distribution operations to 3PLs, according to a report from real estate firm CBRE.
Specifically, 3PLs’ share of bulk industrial leasing activity—covering leases of 100,000 square feet or more—rose to 34.1% through Q3 of this year from 30.6% through Q3 last year. By raw numbers, 3PLs have accounted for 498 bulk leases so far this year, up by 9% from the 457 at this time last year.
By category, 3PLs’ share of 34.1% ranked above other occupier types such as: general retail and wholesale (26.6), food and beverage (9.0), automobiles, tires, and parts (7.9), manufacturing (6.2), building materials and construction (5.6), e-commerce only (5.6), medical (2.7), and undisclosed (2.3).
On a quarterly basis, bulk leasing by 3PLs has steadily increased this year, reversing the steadily decreasing trend of 2023. CBRE pointed to three main reasons for that resurgence:
Import Flexibility. Labor disruptions, extreme weather patterns, and geopolitical uncertainty have led many companies to diversify their import locations. Using 3PLs allows for more inventory flexibility, a key component to retailer success in times of uncertainty.
Capital Allocation/Preservation. Warehousing and distribution of goods is expensive, draining capital resources for transportation costs, rent, or labor. But outsourcing to 3PLs provides companies with more flexibility to increase or decrease their inventories without any risk of signing their own lease commitments. And using a 3PL also allows companies to switch supply chain costs from capital to operational expenses.
Focus on Core Competency. Outsourcing their logistics operations to 3PLs allows companies to focus on core business competencies that drive revenue, such as product development, sales, and customer service.
Looking into the future, these same trends will continue to drive 3PL warehouse demand, CBRE said. Economic, geopolitical and supply chain uncertainty will remain prevalent in the coming quarters but will not diminish the need to effectively manage inventory levels.
In a push to automate manufacturing processes, businesses around the world have turned to robots—the latest figures from the Germany-based International Federation of Robotics (IFR) indicate that there are now 4,281,585 robot units operating in factories worldwide, a 10% jump over the previous year. And the pace of robotic adoption isn’t slowing: Annual installations in 2023 exceeded half a million units for the third consecutive year, the IFR said in its “World Robotics 2024 Report.”
As for where those robotic adoptions took place, the IFR says 70% of all newly deployed robots in 2023 were installed in Asia (with China alone accounting for over half of all global installations), 17% in Europe, and 10% in the Americas. Here’s a look at the numbers for several countries profiled in the report (along with the percentage change from 2022).
Sean Webb’s background is in finance, not package engineering, but he sees that as a plus—particularly when it comes to explaining the financial benefits of automated packaging to clients. Webb is currently vice president of national accounts at Sparck Technologies, a company that manufactures automated solutions that produce right-sized packaging, where he is responsible for the sales and operational teams. Prior to joining Sparck, he worked in the financial sector for PEAK6, E*Trade, and ATD, including experience as an equity trader.
Webb holds a bachelor’s degree from Michigan State and an MBA in finance from Western Michigan University.
Q: How would you describe the current state of the packaging industry?
A: The packaging and e-commerce industries are rapidly evolving, driven by shifting consumer preferences, technological advancements, and a heightened focus on sustainability. The packaging sector is increasingly prioritizing eco-friendly materials to reduce waste, while integrating smart technologies and customizable solutions to enhance brand engagement.
The e-commerce industry continues to expand, fueled by the convenience of online shopping and accelerated by the pandemic. Advances in artificial intelligence and augmented reality are enhancing the online shopping experience, while consumer expectations for fast delivery and seamless transactions are reshaping logistics and operations.
In addition, with the growth in environmental and sustainability regulatory initiatives—like Extended Producer Responsibility (EPR) laws and a New Jersey bill that would require retailers to use right-sized shipping boxes—right-sized packaging is playing a crucial role in reducing packaging waste and box volume.
Q: You came from the financial and equity markets. How has that been an advantage in your work as an executive at Sparck?
A: My background has allowed me to effectively communicate the incredible ROI [return on investment] and value that right-size automated packaging provides in a way that financial teams understand. Investment in this technology provides significant labor, transportation, and material savings that typically deliver a positive ROI in six to 18 months.
Q: What are the advantages to using automated right-sized packaging equipment?
A: By automating the packaging process to create right-sized boxes, facilities can boost productivity by streamlining operations and reducing manual handling. This leads to greater operational efficiency as automated systems handle tasks with precision and speed, minimizing downtime.
The use of right-sized packaging also results in substantial labor savings, as less labor is required for packaging tasks. In addition, these systems support scalability, allowing facilities to easily adapt to increased order volumes and evolving needs without compromising performance.
Q: How can automation help ease the labor problems associated with time-consuming pack-out operations?
A: Not only has the cost of labor increased dramatically, but finding a consistent labor force to keep up with the constant fluctuations around peak seasons is very challenging. Typically, one manual laborer can pack at a rate of 20 to 35 packages per hour. Our CVP automated packaging solution can pack up to 1,100 orders per hour utilizing a fully integrated system. This system not only creates a right-sized box, but also accurately weighs it, captures its dimensions, and adds the necessary carrier information.
Q: Beyond material savings, are there other advantages for transportation and warehouse functions in using right-sized packaging?
A: Yes. By creating smaller boxes, right-sizing enables more parcels to fit on a truck, leading to significant shipping and transportation savings. This also results in reduced CO2 emissions, as fewer truckloads are required. In addition, parcels with right-sized packaging are less prone to damage, and automation helps minimize errors.
In a warehouse setting, smaller packages are easier to convey and sort. Using a fully integrated system that combines multiple functions into a smaller footprint can also lead to operational space savings.
Q: Can you share any details on the typical ROI and the savings associated with packaging automation?
A: Three-dimensional right-sized packaging automation boosts productivity significantly, leading to increased overall revenue. Labor savings average 88%, and transportation savings accrue with each right-sized box. In addition, material savings from less wasteful use of corrugated packaging enhance the return on investment for companies. Together, these typically deliver returns in under 18 months, with some projects achieving ROI in as little as six months. These savings can total millions of dollars for businesses.
Q: How can facility managers convince corporate executives that automated packaging technology is a good investment for their operation?
A: We like to take a data-driven approach and utilize the actual data from the customer to understand the right fit. Using those results, we utilize our ROI tool to accurately project the savings, ROI, IRR (internal rate of return), and NPV (net present value) that facility managers can then use to [elicit] the support needed to make a good investment for their operation.
Q: Could you talk a little about the enhancements you’ve recently made to your automated solutions?
A: Sparck has introduced a number of enhancements to its packaging solutions, including fluting corrugate that supports packages of various weights and sizes, allowing the production of ultra-slim boxes with a minimum height of 28mm (1.1 inches). This innovation revolutionizes e-commerce packaging by enabling smaller parcels to fit through most European mailboxes, optimizing space in transit and increasing throughput rates for automated orders.
In addition, Sparck’s new real-time data monitoring tools provide detailed machine performance insights through various software solutions, allowing businesses to manage and optimize their packaging operations. These developments offer significant delivery performance improvements and cost savings globally.