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.
Don't expect to find Bruce Mantz tooling around Edison, N.J., in a battered 1978 Dodge Dart with a nonworking AM radio and rusty muffler dragging behind. Mantz is nothing if not finicky about his vehicles. At work, he drives only late models with all the bells and whistles, and he prides himself on the care he takes of them. Not a day passes when he doesn't check under the hood, and he has yet to miss a scheduled maintenance check.
But Mantz isn't some Hollywood celebrity with a passion for classic Corvettes or Aston Martins. The vehicles upon which Mantz lavishes so much attention are the 80 lift trucks used to shuttle pallets and cases around the distribution centers run by Automated Distribution Systems. ADS, as it's known, is a third-party logistics service provider that operates five distribution centers totaling 1.6 million square feet of space, and Mantz is the company's director of operations.
Though he may be fussy about the lift trucks' ergonomic features and options, he's downright finicky about the financing—the leasing and buying particulars. "We want to make sure we're getting machines that will not only serve us well from the standpoint of productivity and driver comfort," Mantz says, "but that will also serve us well financially."
With a fleet of 80 vehicles, Mantz has the kind of negotiating clout and buying power most managers can only dream of. And over the past 10 years, Mantz has purchased his share of lift trucks outright. But lately, leasing's been his option of choice. "When you couple [the convenience] with some very attractive promotions from the manufacturers and dealers, [and factor in] the very favorable interest rates," he says, "leasing has become a no-brainer for us."
High interest in low interest
Mantz isn't alone. Lift truck manufacturers like Raymond and Yale report a surge in leasing activity in the last several years. Part of it's the low interest rates, says Warren Eck, vice president of Yale Fleet and Yale Financial Services. "[A] lot of it has to do with the cost of money being as low as it has been the last couple years."
before you sign on the dotted line …
You've seen the demo model and kicked the tires, but do you really know what you'll be getting into when you sign that lift truck lease? To avoid unpleasant surprises, the Equipment Leasing Association recommends that you ask yourself the following 10 questions before you sign on the dotted line.
1. How am I planning to use this equipment?
2. Does the leasing representative understand my business and how this transaction helps me to do business?
3. What is the total lease payment and are there any other costs that I could incur before the lease ends?
4. What happens if I want to change this lease or end the lease early?
5. How am I responsible if the equipment is damaged or destroyed?
6. What are my obligations for the equipment (such as insurance, taxes and maintenance) during the lease?
7. Can I upgrade the equipment or add equipment under this lease?
8. What are my options at the end of the lease?
9. What are the procedures I must follow if I choose to return the equipment?
10. Are there any extra costs at the end of the lease?
Another part is that with leasing, customers don't have to scrape up cash for a deposit and all the incidental expenses surrounding a lift truck purchase. Banks normally won't allow customers to roll the incidental costs—freight charges, installation fees and maintenance costs—into an equipment purchase loan. But leasing terms aren't nearly so restrictive—customers can usually obtain 100-percent financing. Leasing can also cut down on record-keeping and paperwork. If the lease includes maintenance costs, for example, the lessor usually issues a single invoice each month that covers the entire fleet, instead of sending separate invoices for each truck. For large fleets, in particular, the savings can add up quickly.
"Leasing is clearly becoming more popular because it leaves cash in your company," says Loren G. Swakow, vice president at Scott Lift Truck Corp., a Komatsu dealer based in Chicago. "Cash is king with businesses, and leasing retains cash."
It hasn't hurt that lift truck manufacturers have been out on the road educating the industry about the advantages of leasing. In the past, many customers shied away from leasing, bewildered by the many options and intimidated by the financial, legal and tax terminology. Now there's help. Kevin Trenga, director of marketing for Raymond Corp., says almost all major manufacturers and dealers have Internet tools on their Web sites to help customers determine if leasing is the right choice for them. Truck buyers are proving to be willing students. "Customers are a lot smarter," says Eck. "They're thinking … more about planned replacement programs so they can structure their lease for the right period of time and replace their machines when they need to."
Not my problem
Low interest rates may attract customers to leasing in the first place, but once they try it, they often discover a host of other benefits. One is insurance against obsolescence. Managers like Mantz who run third-party DCs tend to place a high premium on using the latest technology. By leasing its trucks, ADS can operate them for a specified term—say, five years—and then upgrade its fleet at the lease's conclusion.
Another advantage is that reselling the equipment becomes someone else's problem. That's also a big plus for Mantz, who says it can be difficult to recoup his investment when it comes time to sell his highly specialized trucks. To operate in ADS's highly automated centers (which feature pick and put to light systems, bar-code tracking and wire guidance systems), lift trucks must be outfitted with expensive RF devices and equipped with wire guided technology for picking in very narrow aisle (VNA) applications. All those costly extras tend to limit the pool of potential buyers when the equipment comes up for resale. "It's hard to get those dollars back,"Mantz admits. "We're running some very specialized machines, and after you've run them for a few years, it can be tough to sell them in the aftermarket. Not everyone has those kinds of applications."
These days, ADS leases its trucks from Raymond, Crown and Sweden-based Atlet, typically for a five-year term, then exchanges them for an upgrade at the conclusion of the lease. That works out well for a company like ADS that's scrupulous about maintaining its equipment and runs a clean facility. At the end of the term, the vehicles are still in excellent condition and have a high residual value.
But that's not true for everyone. Companies that operate their trucks for multiple shifts or use them in harsh environments may well find that their trucks have a pretty low residual value at the end of a lease. For them, purchasing might be a better option. "A real dirty application like a steel mill or a foundry is probably not the best candidate for leasing," says Eck. "The same holds true for somebody running a lot of hours, maybe 3,000-plus hours a year."
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]."