Boasting prime locations near efficient transportation infrastructures, Central New Jersey and Pennsylvania's Lehigh Valley were born to run distribution centers.
Susan Lacefield has been working for supply chain publications since 1999. Before joining DC VELOCITY, she was an associate editor for Supply Chain Management Review and wrote for Logistics Management magazine. She holds a master's degree in English.
As delivery windows get tighter and transportation costs soar, it becomes increasingly important to maintain a distribution center or warehouse close to your customers. For this reason, more and more companies are finding it necessary to establish a distribution center in the densely populated Northeast.
For the past year, DC Velocity has been looking at logistics hubs or "clusters"—those cities or regions that attract both logistics service providers and the logistics operations of manufacturers, retailers, and distributors. The past two articles have focused on emerging logistics hubs, locations that are growing in importance but may not be as well known as, say, Memphis, Tenn.; California's Inland Empire; or Columbus, Ohio. Identifying emerging logistics hubs for the Northeast region, however, is problematic. After all, the Northeast has been a center of logistics and trade for centuries.
Despite the long history, two areas in particular are showing significant growth in logistics-related development, and any company evaluating distribution and logistics facilities in the Northeast should consider them: Central New Jersey and Pennsylvania's Lehigh Valley.
CENTRAL NEW JERSEY
New Jersey suffers from a bit of an image problem. Known for high labor costs, red tape, and an unfavorable tax climate, New Jersey has a reputation for being unfriendly to business. CNBC's 2013 list of the most business-friendly states, for example, ranked New Jersey an unimpressive 42nd.
But Tracye McDaniel, president and CEO of the nonprofit economic development corporation Choose New Jersey, argues that when you consider New Jersey, you have to think about the total value proposition, which includes its location, infrastructure, and people.
It's hard to deny that Central New Jersey is, in McDaniel's words, "perfectly located." New Jersey is within a day's drive of more than 130 million consumers with a total disposable income of $3 trillion.
The central part of the state also provides easy access to all the major modes of transportation: road, rail, air, and ocean. Major highways include I-95, I-76, I-78, and I-80. The Port of New York & New Jersey is the largest port on the East Coast of North America and the third-largest in the nation, behind only Los Angeles and Long Beach, Calif. Newark Airport is the nation's 14th busiest airport, handling 80,000 tons of cargo a year. The state also has 1,000 miles of rail freight lines.
Significant investments continue to be made in that infrastructure, particularly at the ports. For example, the Port of New York & New Jersey is in the midst of a major redevelopment effort to deepen the harbor, improve terminals, and strengthen inland access. A case in point is the $600 million ExpressRail System program, which has created dedicated rail facilities, additional support track, and rail yards for each of the port's major container terminals. An additional $1.3 billion is being spent to raise the Bayonne Bridge, which connects Bayonne, N.J., to Staten Island. Raising the bridge to 215 feet over the high-tide level from 155 feet will allow larger containerships to reach Port Newark and Port Elizabeth. Additionally, a new breakbulk facility, the Port of Paulsboro, is under construction on the Delaware River.
The state also has a readily available, highly skilled work force, according to McDaniel. To make it easier for companies to find qualified logistics and distribution professionals, the state has created a Transportation, Logistics, and Distribution Talent Network to address workforce needs and connect potential employers and employees.
For these reasons, many **ital{Fortune} 500 companies, such as Home Depot, Barnes & Noble, and Toys R Us, have distribution facilities in the state. And more are coming, says McDaniel. For example, Amazon.com announced that it is building a 1 million-square-foot DC in Robbinsville, N.J. Industrial real estate company Prologis is building a 900,000-square-foot distribution center in Jersey City, which will be shared by online grocer Peapod and Imperial Bag and Paper Co. Subaru has begun construction on a 526,050-square-foot parts distribution center and training facility in Florence, N.J. In total, there are between 1,800 and 1,900 distribution centers in Central New Jersey, according to McDaniel.
Finally, McDaniel stresses the progress that Gov. Chris Christie and the current legislature have made to make the state more welcoming to business. As examples she cites the recently passed Economic Opportunity Act, which overhauls the state's incentive program, and the establishment of the Red Tape Review Commission, which works to reduce cumbersome regulations and make them less costly for business.
LEHIGH VALLEY, PA.
Located 80 miles from New York City and 60 miles from Philadelphia, Pennsylvania's Lehigh Valley sits at a sweet spot in the Northeast Corridor. "From this location, companies can reach 65 percent of the customers in the U.S. in a day's drive out and back," says Don Cunningham, CEO of the Lehigh Valley Economic Development Corp. (LVED). "And for the most part, we offer a lower-cost alternative [to] the larger metropolitan areas of North Jersey and New York."
Indeed, this section of Eastern Pennsylvania offers labor rates and land taxes that are lower than the more urban areas of the Eastern Seaboard. Additionally, transportation costs are quite favorable, as the area has strong rail service and a good road network, including I-78, which provides a direct route into New York City, Newark, and the surrounding ports. The area also has more land available than the congested regions around the major metropolitan areas and the ports.
All of these factors have contributed to an explosion in DC growth in the region during the past 15 years. According to LVED, the Lehigh Valley has gone from having 16 million square feet of total distribution space in 1997-1998 to the current total of 41 million square feet. Companies with distribution centers in the region include BMW, Amazon, and Walgreens. Additionally, National Freight Industries (NFI) is constructing a 980,000-square-foot warehousing and distribution facility that it will operate on behalf of Ocean Spray.
Interest in the region is still flourishing, as evidenced by an industrial vacancy rate of just 6 percent and the fact that real estate firm Liberty Property Trust recently spent $60 million on spec for a 1.2 million-square-foot warehouse. Development is not limited to distribution. According to Cunningham, more and more companies are also moving their production facilities into the region to take advantage of cost efficiencies from producing and distributing from the same spot.
That development will not be slowing anytime soon. "We expect to remain hot for several years," says Jarrett Witt, vice president of economic development for LVED. "The issue becomes when and if the region runs out of the land desired by larger distributors."
In fact, Witt and Cunningham say the region's biggest competition is not New Jersey, New York, or Maryland but other, more rural areas of Pennsylvania where land is still plentiful and prices are lower.
Where the Lehigh Valley has an advantage over these rural areas in South and Central Pennsylvania is its labor pool. "Our work force is bigger and better qualified," says Cunningham.
Due to the area's roots in heavy manufacturing—Bethlehem Steel was located there and Mack Trucks still operates a plant there—the community colleges in the Lehigh Valley have strong vocational and technical training programs. In addition, Lehigh University, located in South Bethlehem, has a well-known supply chain management program at both the graduate and undergraduate level.
Coming up: In the December issue, DC Velocity will look at emerging logistics hubs in the U.S. West.
For more information ...
Want to learn more about the logistics clusters mentioned in this article? Here's where to find more information:
New Jersey
Choose New Jersey: This independent, nonprofit economic development organization offers a wealth of information about New Jersey on its website, with sections on demographics, top industries, and site selection.
Port of New York & New Jersey: The port authority's website outlines the port's services and redevelopment initiatives.
New Jersey Transportation, Logistics, and Distribution Talent Network: Funded by the New Jersey Department of Labor and Workforce Development, this organization seeks to help educational institutions develop programs to fulfill employers' needs, provide networking opportunities, and raise awareness about jobs in the field.
Lehigh Valley, Pa.
Lehigh Valley Economic Development Corp.: This organization helps companies relocate to the Lehigh Valley. Its website includes information on demographics and incentive programs as well as site selection data.
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]."