Take an ideal location and an engaged business community, throw in some world-class barbeque, and Kansas City may have the recipe for 21st century supply chain success.
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.
It rests on America's logistics axis, the focal point for much of the nation's freight moving in any direction. It handles more rail tonnage than any city in the country and more rail cars than any city except Chicago. It is bisected by two major interstate highways: I-35 running north to south, and I-70 from east to west. Its airport handles more cargo than any facility covering a six-Midwestern-state radius other than O'Hare International Airport. Its bi-state, 18-county region boasts more road lane capacity than any of comparable size, which might explain why "rush hour" is a largely alien concept even though more than 2 million people call it home.
It also serves up the meanest barbeque anywhere in creation.
Yet Kansas City, Mo., remains one of the world's most overlooked commerce centers, a reality not lost on its devoted community of business leaders and civic boosters. Upon arrival, visitors will usually be greeted by a boisterous "Welcome to Kansas City!" followed by, "Is this your first time here?" with the tacit understanding that the reply is often affirmative.
Kansas City's image has long been that of a "large small city" dwarfed by Chicago, 500 miles to the northeast, and by its sister city on Missouri's eastern rim, St. Louis, with the latter having a reputation for being more cosmopolitan than Kansas City and with stronger ties to East Coast culture and commerce.
None of that seems to bother the locals. They revel in Kansas City's label as the original "cow town," a phrase coined decades ago after the preponderance of cattle roaming its streets. As they see it, their city's central location makes it—not Chicago or St. Louis—the natural eastern gateway to the west, as well as the ideal northern consolidation point for truck and rail service supporting the booming U.S.-Mexico trade.
Yet for all its strengths as a rail center, Kansas City still lacks the established gateway status of a city like Chicago, where all seven North American Class I railroads come together. Patrick Ottensmeyer, executive vice president and chief marketing officer for Kansas City Southern Inc. (KCS), the Kansas City-based railway, said it is more efficient for shippers and carriers to go direct into Chicago without the need for an interchange at Kansas City.
Still, Ottensmeyer said that, in many cases, Kansas City is the "perfect set-up" for rail movements, especially given its position as a median point for north-south traffic moving between the upper Midwest and Mexico. To leverage the region's pre-eminence as a source of animal protein products, KCS is considering a "shuttle" service at Kansas City under which the railroad would load beef and poultry shipments brought in by truck and then ship it southbound to Mexico, Ottensmeyer said. KCS would carry Mexican produce on the northbound leg, he said.
Chris J.F. Gutierrez, president of KC SmartPort, a non-profit economic and logistics development organization, said Kansas City actually benefits from having Chicago considered a rival for supply chain projects. "Most supply chain professionals know the difficulty of congestion, labor, and other factors that challenge them in Chicago," Gutierrez said in an e-mail to DC Velocity. "Kansas City does not have these issues and offers a competitive option for [a] company to consider."
Gutierrez said that when Kansas City is in the running as a site for a new manufacturing or distribution center, "we rarely are competing against Chicago."
Location, location...
When it comes to attracting industrial development, however, Kansas City still has some work to do. Local financial institutions, by and large, adhere to very conservative lending practices. As a result, there is little, if any, so-called speculative development of industrial properties. While that served the city in good stead during the economic downturn, it has made it hard to aggressively and creatively market a property to a business looking to quickly expand or relocate into an existing facility.
But the city's many supply chain strengths can offset the impact of its lenders' practices. When the Coleman Co. Inc., the Wichita, Kan.-based maker of outdoor products, looked to build a 1.5 million-square-foot distribution center—its largest ever—it chose Kansas City, even though St. Louis made a more "financially favorable" proposal, according to Rob Tecco, Coleman's director of distribution.
Kansas City got the nod because of its abundant labor pool, a friendly pro-business climate, and a superior transport network to support Coleman's receiving and distribution, said Tecco. "We think we have a better transportation piece" in Kansas City, he said.
It didn't hurt that the facility was constructed and in move-in condition for Coleman within 10 months after it committed to Kansas City, Tecco added. Coleman moved into the DC in October 2009.
Kansas City's proximity to major consumer markets also drove Pure Fishing Inc., one of the world's leading makers of fishing tackle equipment, to build a 400,000-square-foot distribution center there in 2008, according to Jeff Kisling, vice president, North America logistics and services. "Kansas City was the place to be from a cost perspective and from an inventory perspective," he said.
Kisling said Pure Fishing's goods can be delivered anywhere in the United States from its DC in three days or less. This is critical for serving West Coast anglers, who make up a good chunk of the company's customer base, he said.
"We can take an order on Monday, ship it out on Tuesday, and our West Coast customers can receive it on Friday in time for the weekend," Kisling said. "St. Louis is too far east" to consistently hit those delivery targets, he added.
Municipal support
Logistics has also been embraced at the municipal level. Perhaps the most striking example is in the western suburb of Olathe, Kan., where over the past 40 years its residents have helped finance—in conjunction with federal and state funding—the construction of four interchanges off I-35. The first three focused on retail and office development. The fourth, and last, was dedicated to industrial development. It opened three years ago.
Tim McKee, president of the Olathe Chamber of Commerce, said the projects have yielded financial benefits far in excess of their costs. "For each interchange that we have built, we have seen private investment of more than $1 billion," he said.
But perhaps the most ringing endorsement to date of Kansas City's increasing relevance on the logistics map can be found in Edgerton, Kan., about 25 miles southwest of the city off I-35. There, workers are erecting an intermodal and distribution complex that will occupy more than 7 million square feet and cost about $750 million, 80 percent of which will be funded through private sources. An additional $100 million in public money will be spent on infrastructure such as access roads around the park.
The project, considered one of the most important development efforts in the history of Kansas, is expected to create more than 13,000 direct and indirect jobs statewide and generate about $1.7 billion in tax revenue over a 20-year period, according to state estimates.
Anchoring the complex will be a $250 million intermodal yard being built by BNSF Railway. The BNSF terminal, slated to open in the fourth quarter of 2013, will replace a smaller facility near the city and become a linchpin of the railroad's southern corridor connecting Chicago and the Southwest. At full capacity, the facility will be able to handle 1.5 million intermodal "lifts" per year, compared with 313,621 lifts handled at the existing facility in 2011. A lift is defined as one trailer or container being placed on or taken off a rail car.
Ground was broken at the BNSF facility in mid-March, and the project is expected to take about 22 months to complete. For BNSF executives, the contrast between the progress at Edgerton and an ongoing project in Southern California, which is in its eighth year of development and remains mired in bureaucratic and environmental red tape, could not be starker.
"We have to get your spirit out there," remarked John Lanigan, BNSF's executive vice president and chief marketing officer, at a conference in Kansas City in early April.
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]."