David Maloney has been a journalist for more than 35 years and is currently the group editorial director for DC Velocity and Supply Chain Quarterly magazines. In this role, he is responsible for the editorial content of both brands of Agile Business Media. Dave joined DC Velocity in April of 2004. Prior to that, he was a senior editor for Modern Materials Handling magazine. Dave also has extensive experience as a broadcast journalist. Before writing for supply chain publications, he was a journalist, television producer and director in Pittsburgh. Dave combines a background of reporting on logistics with his video production experience to bring new opportunities to DC Velocity readers, including web videos highlighting top distribution and logistics facilities, webcasts and other cross-media projects. He continues to live and work in the Pittsburgh area.
One of the promotional slogans the state of Ohio has used over the years is "Ohio, the heart of it all." Although it might not be quite what the sloganeers had in mind, the motto seems particularly apt from a logistics perspective. Centrally located in the nation's heartland, Ohio offers easy access to virtually all major markets on the eastern half of the continent.
"From a supply chain perspective, Ohio is ideally situated to reach the majority of the U.S. population and its businesses," says Art van Bodegraven, president of the Columbus-area supply chain consulting firm Van Bodegraven Associates. "Ohio also has a very business-friendly government structure," he adds.
Ohio's government has become more business-friendly than ever over the past six years. During his 2007-2011 term in office, former Gov. Ted Strickland eliminated over 250 state business regulations and revised another 1,800 in a bid to attract industry. He also streamlined business taxes, eliminating the corporate franchise and inventory taxes. On top of that, the governor used $100 million in federal stimulus money to invest in infrastructure, including a new intermodal hub in North Baltimore, Ohio, to handle goods moving via rail to and from Mid-Atlantic ports. The initiative is expected to save Ohio $70 million in highway maintenance and reduce logistics costs for Ohio companies by $350 million.
Under Strickland's leadership, Ohio's business climate jumped in the rankings from 38th in the nation to number 11. Those efforts have continued under Gov. John Kasich, who was sworn into office last year.
JOB ONE
Ohio's efforts to attract business have gone beyond regulatory and tax reform. The state has also made job creation a priority. To that end, it established JobsOhio early last year. (JobsOhio was privatized as a nonprofit entity in July of that year.) The agency has been given power by the state to negotiate incentives, grants, and other enticements to lure new business and to encourage growth in existing operations.
Significantly for the transportation and supply chain community, one area of focus is logistics. "The state government identified nine industry clusters that it felt was important to growth, and logistics is one of the nine," says Mark Patton, general manager of bio/health, information services, and logistics at JobsOhio. He says that manufacturing and logistics are tightly coupled in Ohio, and many companies are moving their operations back from China to Ohio as automation has reduced China's labor cost advantage. "They are finding it is more expensive to move products a long distance than to manufacture it here," Patton explains.
To meet expected growth in manufacturing, transportation, and distribution, the state has committed to supporting logistics infrastructure in several key areas. One of those areas is its extensive interstate highway system, which allows easy reach to both U.S. and Canadian commercial and population centers. Some 60 percent of U.S. citizens and 50 percent of Canadians live within a 600-mile radius of the state.
Ohio also offers easy rail access. Containers arriving at the Port of Norfolk (Virginia) can reach Ohio within a day by rail. The state also boasts 13 intermodal terminals. That compares favorably with California, which has 10 intermodal terminals in a much larger geographic region. In addition to rail, shippers of bulk products have the option of moving goods via Lake Erie to the north and along the Ohio River, which makes up the state's southern border.
As for air service, cargo handling facilities are available at the state's commercial airports as well as the Rickenbacker Inland Port in Columbus, a freight-only airpark. And the field is about to get bigger: The former DHL hub in Wilmington, Ohio, is now being redeveloped as a logistics air hub. After DHL pulled out in January 2009, the company donated the airport and adjacent buildings to the Clinton County Port Authority. Last year, the county hired real estate services firm Jones Lang LaSalle to develop a master plan for its use.
"The plan calls for the airpark to become a multi-use, aviation-based business park. Among the uses is as an international air freight center," says David Lotterer, a senior associate with Jones Lang LaSalle. "If you're going to bring in products by air and then distribute by land, it is an excellent site."
HOME GROWN
Just as Ohio is a convenient location for logistics and distribution, it is well situated for businesses that serve the supply chain community. For example, Intelligrated, one of the world's largest automated material handling systems manufacturers, is located in Mason, Ohio, just a stone's throw from Cincinnati. Company officials say the Midwest location makes it easy to ship products to the majority of its customers as well as to visit their sites.
"Clearly, having many of our customers nearby is a great advantage," says Chris Cole, Intelligrated's CEO. Key Intelligrated customers in Ohio include Anheuser-Busch, Big Lots, Cardinal Health, Georgia Pacific, Kraft, PepsiCo, Procter & Gamble, and Staples, to name just a few.
In 2009, Intelligrated partnered with the Ohio Department of Development and JobsOhio, receiving a $24 million incentive package to help the company expand. In return, Intelligrated promised to increase its workforce from 537 to 804 by the end of 2012. The company actually surpassed that goal in 2011, and it continues to open new slots, many of which are high-paying engineering and technical positions.
This past January, Intelligrated broke ground on a new 108,000-square-foot facility at its Mason headquarters to accommodate its engineering, customer service, research and development, and testing facilities - in all, 450 workers will be housed there.
"The state has been great to work with, including the various port authorities. And the city of Mason has also been a tremendous partner in helping our company to grow," says Cole. "We have seen that in an era when many have doubted America's manufacturing abilities, we have proven that a quality product can be made right here at home."
Among the reasons why companies like Intelligrated choose to locate or expand in Ohio is the region's talent pool.
"We have a very well-educated workforce with a strong work ethic," says Van Bodegraven. "Ohio is good at developing job skills. People can start learning about logistics in high school and end up with a Ph.D. in logistics at Ohio State."
John Ness, president of ODW Logistics, concurs. "People here have a Midwestern work ethic that is to 'promise your best, and deliver [on] your promise,'" he says.
ODW, a Columbus-based third-party logistics service provider, operates from 16 locations in nine states, with half of its operations in Ohio. Ness cites Ohio's labor pool, available and affordable real estate, low labor costs, freight access, and favorable business climate as major reasons why logistics has a strong foothold in the state.
In addition to his duties at ODW, Ness serves as co-chair of the Columbus Regional Logistics Council, a group formed to promote growth in the region's logistics capabilities. Recently, the council has been working with Columbus State Community College to retrain dislocated workers for jobs in logistics. Administered through the Central Ohio Workforce Commission, the training program has utilized a federal grant of $4.6 million to graduate over 600 logistics students over the past two years. It also has a 74-percent job placement rate for its grads.
DEEP ROOTS IN THE BUCKEYE STATE
Another material handling equipment maker with deep roots in the Buckeye State is Crown Equipment Corp. Since 1956, Crown has shipped lift trucks made at its facilities in New Bremen, north of Dayton, to customers worldwide.
Like Intelligrated, Crown has partnered with the state on a number of initiatives. Jim Mozer, Crown's senior vice president, points to fuel cell development as an example. Ohio has awarded Crown Equipment two $1 million grants for the development and testing of fuel cell-powered forklifts, he says. With these funds, Crown has built more than 500 new fuel cell forklifts and reconfigured many of its existing vehicles to operate with fuel cells.
During the past three years, Crown has also received more than $250,000 in training grants from the state. In return, Crown has purchased and revitalized empty facilities within Ohio. Last year, it acquired a vacant 75,000-square-foot facility in Minster to house its wire harness assembly operations. Crown also revitalized the former Huffy bicycle manufacturing site in Celina, turning it into a vibrant 850,000-square-foot manufacturing facility for lift truck products.
"Ohio has been a key part of Crown's growth as a global material handling company, and I hope that state officials would say the same thing about Crown's role in Ohio's emergence as an international logistics hub," says Mozer. "The supply chain and logistics community in the state has provided a valuable ecosystem of resources for our customers. We've found that Ohio is an excellent place for us to do business."
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]."