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.
In the brave new world of retail distribution, companies must be flexible, accurate, and fast. That's especially true for those involved in omnichannel distribution, where retail, wholesale, catalog, and direct-to-consumer orders may be processed and shipped from the same facility. These retailers must adjust to new ways of doing business.
"If you look at the attributes of omnichannel, it increases complexity, decreases order size, and puts a burden on retailers to do distribution in a more cost-effective way," says Ron Kubera, senior vice president and general manager of voice company Vocollect, a division of Honeywell.
Keith Phillips, president and CEO at voice provider Voxware, reports that when retailers first move into multichannel fulfillment, they often discover that their distribution it is not as efficient as it should be. "The biggest challenge to omnichannel is that many retailers do not do their fulfillment that well," he says. "Where they are failing is not on the shopping experience, but on the fulfillment. What used to be seen as a necessary evil is now a critical part of the overall customer experience."
HEAR FOR THE TAKING
With its reputation for speed, flexibility, and accuracy, voice technology offers retailers a way to address the complexity of the omnichannel environment. "Their number one concern is how do they do e-commerce right and best utilize their assets. It is their biggest fear, and yet it is their biggest opportunity," says Greg Cronin, executive vice president at Intelligrated's Knighted division, a provider of voice systems.
Voice can help companies make the best use of their assets by providing a common platform for nearly every operation in the facility. While picking has always been voice's sweet spot, the technology can also be applied in receiving, putaway, replenishment, inventory management, shipping, and more.
"When you look at the entire process from end to end, there are a lot of manual activities," notes Voxware's Phillips. "Anytime you see a lot of manual tasks, voice can help."
And if a particular technology works for one channel, it is easy to see why companies would want to apply it to other channels as well.
"If I am doing fulfillment of one channel, why can't I take advantage of the economies of scale and use it for other channels too?" asks Bob Bova, CEO and president of voice provider Vangard Voice.
The flexibility of voice enables users to move easily from one DC task to another, while utilizing the same basic equipment. Few other technologies boast that capability.
THE RIGHT PRODUCT, OR ELSE
Among the challenges retailers face when moving to omnichannel distribution is the need to step up their game when it comes to order accuracy. If the wrong product is delivered to a company store, it's not such a big deal. The inventory is still within the company's system—records can be updated, the inventory reallocated, and the correct product delivered in the next shipment. But it's not that simple with direct-to-consumer orders.
"High 90s accuracy is not good enough with direct-to-consumer," notes Voxware's Phillips. "Sending the wrong item can be deadly. Those who don't figure it out are going to be facing severe consequences."
Rob McKnight, program manager for voice solutions at Intelligrated's Knighted, concurs. "Fast is nice, but it's not good to ship the wrong thing fast," he says.
As it happens, accuracy is one of voice's biggest strengths. To assure the right items are picked, voice systems include a confirmation procedure that uses check digits. The check digit, usually a series of three numbers, is attached to each pick location. The voice system first directs a worker to the assigned location. Upon arrival, the worker must read off the check digit to confirm that he or she is picking from the correct shelf or bin. As a result, voice is able to produce accuracy rates of 99 percent-plus.
Another advantage of voice is its ability to facilitate labor management. Forecasting and planning are not easy with omnichannel distribution. While store deliveries can be fairly predictable, Internet orders are not. They vary by day, season, and whim. Voice allows managers to shift labor to whatever area of the operation has the greatest need. Workers can use the same device, doing store replenishment one moment, handling putaway the next, and filling a direct-to-consumer order later. Most voice systems operate in real time with the flexibility to adjust assignments on the fly.
"When I have a piece of paper and I find a need to do something different, I need to go get another piece of paper. Voice offers real-time interleaving. It can redirect the work as needed," explains Jennifer Lachenman, vice president of product strategy at Lucas Systems, a voice technology provider.
Voice systems provide workers with step-by-step verbal instructions for performing their tasks, which makes training a snap. Workers simply have to be able to follow directions. As a result, training time is reduced to a few hours, compared with days for many other technologies.
"With voice, training is incredibly easy," says Ryan Absil, project manager for voice provider topVox. "You just go through the dialogue. Working with voice is like having a supervisor with you all the time helping you."
And while voice is designed to manage the process, employees still have the flexibility to adjust their work as needed. For instance, a worker assigned to putaway might encounter a situation where he or she is told to deposit a product in a location already occupied by another item. Voice allows that worker to change the assigned location simply by informing the voice system of the new storage location. Likewise, if a worker can't find a product he or she has been assigned to pick, that worker can simply ask the system to send him or her to a redundant location that holds the same stock-keeping unit (SKU).
"Voice strikes a nice balance of worker autonomy with the enforcement of best practices," says Lachenman of Lucas Systems.
Voice systems also offer visibility tools that can be used for monitoring worker performance. Managers can easily see where bottlenecks are occurring. They can also analyze individual worker performance to see where additional instruction and support are needed to help all members of a team reach their potential.
"The visibility tools are an important part in empowering the supervisors and other stakeholders who need immediate information," says John Schriefer, manager of marketing communications at Lucas Systems.
THE ENDLESS WAREHOUSE
One of the biggest changes brought about by omnichannel distribution is that order processing is no longer limited to the warehouse. Many retailers view their stores as extensions of their distribution centers. Customers can order online and pick up at the store. Stores can also be used to process returns. On top of that, online orders that might typically be filled in a DC can be assigned to a retail store to pick and pack. For example, some grocery chains are picking Internet orders directly from store shelves for local delivery or customer pickup. Voice vendors are now developing applications that will allow their technologies to be used at the store level.
In addition to order fulfillment, voice can be applied to store replenishment tasks and used for taking inventory. All of these are labor-intensive tasks that are performed by store personnel that are often paid better than warehouse workers. As a result, having efficient systems in the retail outlets is essential to the bottom line.
"Doing distribution from stores is offered as a service, but it is hard to make a profit at it," says Steve Hoffman, technology and fulfillment specialist at systems integrator Dematic. Hoffman explains that even though in-store distribution is a loss-leader, retailers believe they have to offer that option to customers. "The more you can do in the store with less labor, the better, even it is not profitable," he adds.
Using voice also makes store employees look less like warehouse workers. Instead of holding a scanner or pick list, workers using some voice systems appear as if they are merely wearing a phone earpiece. "When picking in the store, you don't want to upset the experience of the other customers," notes Hoffman. "Voice's ability to be hands-free and eyes-free means that workers won't be running into the customers."
Another advantage of voice is the software's ability to run on a variety of different hardware devices, including in some cases, smartphones and tablets. "We are building layers that make the fulfillment devices agnostic. It gives the customer the choice to use multiple devices operating on the same system," says McKnight of Intelligrated's Knighted.
"This is a new way that companies are applying voice," adds Vangard's Bova. He says that just about any task done in the warehouse or store can be directed by voice utilizing smart devices. "We can voice-enable the operations that the customer is already doing to increase productivity and improve the customer experience," he says.
That kind of flexibility may be voice's biggest selling point when it comes to the omnichannel environment. Whether in the distribution center or a store, it is a technology that can handle just about any process assigned to it.
"It all comes down to flexibility," notes Vocollect's Kubera. "When you look at the dynamics of omnichannel distribution, flexibility is really going to make the difference going forward."
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]."