The toughest job on the planet? interview with Stephen Cahill
If something goes amiss with one of your shipments, you might have an irate customer on your hands. If one of Stephen Cahill's World Food Programme shipments goes awry, people could die.
Mark Solomon joined DC VELOCITY as senior editor in August 2008, and was promoted to his current position on January 1, 2015. He has spent more than 30 years in the transportation, logistics and supply chain management fields as a journalist and public relations professional. From 1989 to 1994, he worked in Washington as a reporter for the Journal of Commerce, covering the aviation and trucking industries, the Department of Transportation, Congress and the U.S. Supreme Court. Prior to that, he worked for Traffic World for seven years in a similar role. From 1994 to 2008, Mr. Solomon ran Media-Based Solutions, a public relations firm based in Atlanta. He graduated in 1978 with a B.A. in journalism from The American University in Washington, D.C.
We all have demanding jobs. But it's all relative.
If one of your shipments is lost, diverted, or delayed, you might have an angry customer or a ticked-off boss, but that's about it. If one of Stephen Cahill's shipments goes awry, people could die.
Cahill's official title is head of contracting, ocean transportation services, for the Rome-based World Food Programme (WFP). Each year, the group coordinates the distribution of more than 4 million tons of relief supplies to over 100 million people who might otherwise go hungry. Half of the food distributed by WFP is transported by ocean to 78 world ports; the rest is sourced in either the country or region where it is needed.
Cahill's role is to ensure that WFP—an arm of the United Nations—is getting the most bang for its food investment buck, and that the food supply chain functions as predictably as possible given the enormous obstacles in its way. The stakes are high: Each night, nearly 1 billion people go to sleep malnourished, according to estimates.
His challenging job is bound to get more so. Global food prices hit record highs in January, the U.N. reported, and are expected to climb 30 percent this year from already-elevated levels. The global population is expected to reach 9 billion people by the year 2050. And a host of issues from geopolitical unrest to climate change to natural disasters show no signs of receding from the world landscape.
The Irish-born Cahill spoke recently with DC Velocity Senior Editor Mark B. Solomon about the myriad challenges facing WFP, and how he manages the enormous, and often life-saving, task in front of him.
Q: In a nutshell, can you describe your mission statement? A: To feed the hungry poor by getting the right commodity to the right place, at the right time, and at the lowest cost.
Q: Do you ever wake up and say to yourself, "The lives of thousands of people—even the fate of governments and nations—may depend on how I do my job today"? A: In some ways, yes. Fortunately, we usually keep three months of in-country stock at any one time to provide a safety net for emergencies. We also have, on average, 30 vessels afloat on any given day that can be used as "floating stock" and can be diverted quickly. I focus more on the fact that, for every dollar saved, we can feed four additional children, and with our annual shipping budget of $250 million, there is a lot of scope to push for additional savings and efficiencies. I also want to ensure that we're getting the best possible value for our money. The difficulty, on a personal level, is measuring the potential cost savings against risks of delays that can directly impact people's lives.
Q: Grain commodity prices have spiked in recent months, and few expect pressures to abate any time soon. How much of this increase is due to traditional supply-demand factors—the needs of a growing global population outpacing production levels—and how much is related to supply chain and logistics challenges? A: I think there are a number of reasons for this. Demand is certainly a factor, with the increased buying power of emerging countries like India and China. However, increased commodity speculation is also a factor. Also, since 2008, financial markets have been very much on edge, so even relatively minor climatic or political events can have a dramatic effect on prices. Further, export restrictions have made the flow of food supplies erratic and unpredictable. This has also impacted prices.
From a supply chain perspective, the market volatility is difficult to deal with, and it has been a negative for the cargo owners and the transporters. Long-term rate stability is essential for owners to invest with confidence and at the same time give shippers the ability to plan properly.
Q: What are the biggest problems you face in getting foodstuffs to market? And how does the tight supply situation make your work more difficult? A: We do not think in terms of "markets." Our focus is on our beneficiaries and the difficulties in reaching them. We work in some of the most remote and difficult places in the world. We are very visible in countries like Somalia, Afghanistan, Haiti, and Democratic Republic of the Congo. In many of those countries, the infrastructure is very poor, and the security situation is often unstable. Bureaucratic red tape is an obstacle, especially as it concerns cargo clearance.
Also, more than 70 countries impose some form of export restrictions that hamper our supply chain. For example, last year when Ukraine imposed an informal export ban, we suddenly had to change our preferred area of supply for Sudan and the Horn of Africa by sourcing from Northern Europe. This increased our lead times considerably.
Q: What steps is your organization taking to mitigate the problems, especially in light of the growing scope of your responsibilities? A: We are involved in a number of initiatives, from local and regional procurement, to rainfall-based insurance in Ethiopia. WFP purchases more than 2 million metric tons of food every year. At least three-quarters of it comes from developing countries. This is because it is WFP's policy, whenever possible, to buy locally produced food. It's close to where we want the cargo, and it provides the local economy with much needed funding.
Q: In 2009, WFP began using a global visibility system from GT Nexus to monitor your network and match supplies with need. How effective has the system been, and what do you see as information technology's role in supporting your work? A: We saw that the platform could offer us a much better insight into our pipeline, and by having that insight, we could adapt our supply chain quickly to the ever-changing environment we work in. An example would be the recent events in Libya, which we use as a corridor to Chad when the corridor through Cameroon is not reliable due to the rainy season. We needed to be able to quickly divert cargo to alternative ports; GT Nexus gives us the visibility to do that.
IT is essential for us. We operate in more than 70 countries, many of which have poor infrastructures and communication systems. We are always looking for better ways to gather and distribute information on our supply chain. Cloud technology certainly seems to me to be the way forward.
Q: Would it be accurate to say that, due to climate change, political unrest, and other factors, nations or regions that were once self-sufficient in food must now import their foodstuffs? If that is true, what additional pressure does this place on the supply chain? A: Climate change is forecast to have a dramatic effect on "rain" irrigated crops. And it's not only about lack of rain, it is also changes in rainy season patterns. Piracy is also affecting our supply chain, especially to countries such as Somalia and Ethiopia, and to one of the ports that we use as a main entry point to Democratic Republic of the Congo, Burundi, Rwanda, Uganda, and Kenya.
We are prepared to work in politically unstable and underdeveloped countries, and our supply chains are designed accordingly. Climate change and food price instability will stress them, but to what extent is difficult to predict.
Q: The U.S. Food Safety Modernization Act signed into law in January imposes new requirements on the food supply chain and gives the Food and Drug Administration more powers to develop a system that will minimize the risk of food-borne illnesses. Do you see, over time, similar programs being implemented globally, and how does this complicate your life? A: As someone involved in food aid, I do not see this as an issue. That said, though, recipient countries have become stricter in the cargo certification process. In some countries, we have to run up to six tests, everything from radiation to bacteriological screening.
Q: If you look at global food needs five years out, what do you expect will be the biggest problem facing the supply chain? A: I look more toward opportunity at the moment. I think "cloud" technology will have a major influence on the supply chain by improving visibility and highlighting actionable bottlenecks. Of course, there will be challenges, most obviously as it concerns the price of oil and petroleum products. In addition, elevated food prices, in and of themselves, have political and commercial consequences. The recent events in Egypt highlight this; the effects on the worldwide food supply chain were negligible. However, had the Suez Canal been closed, the situation would have changed dramatically.
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]."