Despite its early supply chain promise (and Wal-Mart's much-hyped 2003 mandate), the RFID revolution has stalled. Will the demands of omnichannel commerce reignite it?
Ben Ames has spent 20 years as a journalist since starting out as a daily newspaper reporter in Pennsylvania in 1995. From 1999 forward, he has focused on business and technology reporting for a number of trade journals, beginning when he joined Design News and Modern Materials Handling magazines. Ames is author of the trail guide "Hiking Massachusetts" and is a graduate of the Columbia School of Journalism.
The story was supposed to go something like this: On June 11, 2003, Wal-Mart Stores quietly ignited the RFID revolution. On that day, the mega-retailer issued its now-famous mandate decreeing that its top-100 suppliers be ready to place tiny radio-frequency identification (RFID) tags on certain incoming shipments by 2005. Anxious to avoid being tossed off the shelves of the world's largest retailer, most suppliers swallowed hard and fell in line. They invested hundreds of thousands of dollars in tags, readers, and software that would eventually transform supply chains worldwide, and an era was born.
Except that it wasn't.
The reality was that the RFID revolution failed to unfold according to the script. Despite the technology's promise—think absolute inventory accuracy, labor savings, and enhanced sales through better product availability—RFID adoption progressed in fits and starts. Part of the problem was that the technology of the time was buggy. Another part was its cost. In the face of supplier resistance and mounting technical problems, Wal-Mart revised its strategy and expectations. And the vaunted RFID revolution stalled.
Now, 12 years later, that picture has begun to shift again. The explanation lies largely in the emergence of omnichannel commerce. To succeed at omnichannel fulfillment—whether that means offering in-store pickup for online sales, shipping items from store shelves, or funneling orders from phone, catalog, store, and website through a single DC—companies require 360-degree inventory visibility and 100-percent accuracy. RFID can provide those precise stock-tracking capabilities.
OMNICHANNEL DEMANDS COULD CHANGE THE TIDE
Although RFID itself dates back to World War II, its use in the supply chain is a relatively recent phenomenon. Where logistics and supply chain applications are concerned, the rollout of RFID has come in three major waves, says Justin Patton, director of the RFID Lab at Auburn University in Auburn, Ala. The first was sparked by Wal-Mart's famous 2005 deadline for retail case- and pallet-level tagging. That was followed in 2010 by a surge in item-level tagging of apparel and footwear, sparked by the improved performance and falling cost of RFID tags and readers. The latest wave is a rise in tagging driven by the demands of omnichannel fulfillment.
"Omnichannel is a major driver of RFID adoption," Patton says. "Without RFID, you can't tell a customer to go drive to the store and get a specific item, because you don't know what items are there with (sufficient) accuracy."
The use of RFID in the warehouse as a way to boost product-tracking capability is a relatively recent development. Until now, distribution centers have typically used RFID tags for three specific applications: inbound audits for quantity, outbound audits for quantity, and to confirm the contents of parcels in pick/pack operations, he says.
However, as they venture into the world of omnichannel commerce, DCs have discovered new benefits, ranging from simple out-of-stock monitoring to more complex tasks such as opening up inventory visibility to online shoppers.
The pressures of omnichannel fulfillment have given rise to a surge in RFID adoption in the last 18 to 24 months, agrees Melanie Nuce, vice president of apparel and general merchandise at GS1 US, the supply chain standards organization.
"If you talk to any retailer, they'll tell you that RFID is fundamental to omnichannel performance. The retailer needs the right item in the right place at the right time," she says.
It's important to note here that this kind of visibility is predicated on what's known as item-level tagging—that is, affixing RFID tags to individual items, as opposed to cases or pallets. Typically, the process begins when a manufacturer attaches a tag to each object as it's assembled, Nuce says. Assigning a unique identifier to every item is the strategic foundation that allows users to do outbound reads at a manufacturing site in Asia, inbound reads at a U.S. DC, then do another outbound read as each shipment heads to a retailer. Building that complete chain of visibility lets users perform downstream inventory reconciliation, tracking products all the way to store shelves and stockrooms.
"Then, they can integrate that data with their existing enterprise resource planning (ERP) software and go from saying 'This is a hammer or this is a small pink T-shirt' to saying 'This is hammer #1 or hammer #2, and this is small pink T-shirt #3 or small pink T-shirt #4,'" Nuce says.
That ability to reconcile inventory shipments by tracking specific items can be enormously valuable when a client complains that a shipper failed to deliver an entire order. Aided by item-level RFID tagging, the shipper can follow the trail of digital breadcrumbs throughout the supply chain, locating the allegedly missing items, whether they were forgotten on a dock, stacked with pallets, or deposited on the wrong shelf in a retailer's backroom.
APPAREL: ON THE CUTTING EDGE
One sector where RFID has made great inroads is apparel, with an estimated two-thirds of the top 30 U.S. apparel retailers using the technology in either a proof of concept trial, pilot project, or full deployment, according to Bill Hardgrave, a professor at Auburn's Harbert College of Business and co-founder of the university's RFID Lab. But it's not just the mega-retailers that have rallied under the RFID banner. When you look at the top 100 U.S. apparel retailers, about half are now using RFID in some form, Hardgrave says.
Retailers turn to RFID for a variety of reasons. In some cases, they're looking to boost inventory accuracy in order to do a better job of replenishment and reduce stockouts. In others, they're using the tags for purposes of loss prevention or shoe display compliance—i.e., making sure every footwear style stocked in the back room is displayed on the retail floor.
As for why RFID has made such headway in the apparel industry, there are four basic reasons, says Patton. First, the sector has a large variety of stock-keeping units (SKUs), as each style of item typically comes in an array of sizes and colors. At the same time, it has low substitutability, which means that customers are loyal to certain brands and sizes. Many retailers have found that RFID tags allow them to deliver these unique apparel items to customers by tracking every unit.
Third, most apparel items—from jeans to dress shirts—have a big enough profit margin to support the cost of implementing RFID. And finally, clothing materials typically lend themselves to simple attachment of the tags.
BARRIERS CONTINUE TO TOPPLE
While much of the focus has been on RFID adoption in the apparel industry, the field is set to expand. New investment for omnichannel applications has helped RFID overcome some of the obstacles that hampered its first full-scale rollout, like the cost of tags and readers, performance problems in challenging environments (radio waves can't penetrate liquid or metal easily), and the cost of training employees to work with the technology.
In RFID's early years, the price of tags was a major problem for all but the largest adopters, hovering at 50 or 60 cents apiece in 2005. But as production has ramped up (global sales of ultra-high frequency passive tags—the most common type—reached 4 billion in 2014), the cost per tag has fallen to the 7- to 10-cent range, according to the Auburn RFID Lab.
Likewise, although technical problems persist for certain applications, the technology has come a long way in the last few years. Radio waves are absorbed by water and reflected by metal—a real problem if you're trying to read tags attached to beverages or makeup in a warehouse with aluminum-clad walls and steel racks. But those challenges can be surmounted for a slightly higher cost with tagging technologies like near-field communication (NFC) or active RFID.
Security has proved to be another stumbling block. Some companies have expressed concern that hackers could steal the digital data they collect by scanning tagged items as they flow through a warehouse, says Mario Vaccari, who teaches courses on transportation and logistics management at American Public University. To address that fear, researchers are working to devise stronger software protection protocols.
CONNECTING THE DOTS
Despite the recent progress, RFID's day has yet to truly arrive. That will only happen when manufacturers, carriers, warehouses, and retailers begin sharing the data they harvest, experts say.
"We've been doing RFID in retail for five years at the item level, but no retailer requires suppliers to send them the data, so retailers are still blind-receiving items," says Auburn's Patton. "The most fundamental link is the relationship between the manufacturer and the retailer, but we haven't made that jump."
Shipping and logistics operations could see a great impact on their visibility when they finally make this connection.
"When the supplier and retailer have gotten to the point where they're making that data handshake and jumping that gap, that will be the spark, the catalyst for real growth," Patton says.
RFID: Not just for tracking anymore
When it comes to RFID in the warehouse or DC, the technology's role isn't limited to tracking pallets, cases, or individual items. In some operations, RFID has another important function: guiding semi-automated vehicles around the facility.
By embedding RFID transponders in warehouse floors, engineers at Mitsubishi Caterpillar Forklift America Inc. (MCFA) in Houston have created systems that guide turret trucks and order pickers to specific racks and aisles with accuracy of one centimeter, says Perry Ardito, general manager of the Jungheinrich warehouse products group at MCFA. The transponders, which are placed in the warehouse floor at specific distances, communicate with an RFID reader/writer in the lift truck to identify warehouse aisle locations and distances.
When linked to a warehouse management system (WMS), the system can automatically pick up or put away products while following the most efficient path of travel. Further, these networks can boost warehouse safety by automatically slowing lift trucks down before they leave an aisle or by making the vehicle stop, flash its lights, or honk its horn at dangerous intersections in a racking system like cross-aisles and pedestrian aisles, Ardito says.
The system is currently installed at several customer sites in North America and is helping to guide more than a thousand lift trucks at DCs around the world, according to MCFA.
Supply chain risk analytics company Everstream Analytics has launched a product that can quantify the impact of leading climate indicators and project how identified risk will impact customer supply chains.
Expanding upon the weather and climate intelligence Everstream already provides, the new “Climate Risk Scores” tool enables clients to apply eight climate indicator risk projection scores to their facilities and supplier locations to forecast future climate risk and support business continuity.
The tool leverages data from the United Nations’ Intergovernmental Panel on Climate Change (IPCC) to project scores to varying locations using those eight category indicators: tropical cyclone, river flood, sea level rise, heat, fire weather, cold, drought and precipitation.
The Climate Risk Scores capability provides indicator risk projections for key natural disaster and weather risks into 2040, 2050 and 2100, offering several forecast scenarios at each juncture. The proactive planning tool can apply these insights to an organization’s systems via APIs, to directly incorporate climate projections and risk severity levels into your action systems for smarter decisions. Climate Risk scores offer insights into how these new operations may be affected, allowing organizations to make informed decisions and mitigate risks proactively.
“As temperatures and extreme weather events around the world continue to rise, businesses can no longer ignore the impact of climate change on their operations and suppliers,” Jon Davis, Chief Meteorologist at Everstream Analytics, said in a release. “We’ve consulted with the world’s largest brands on the top risk indicators impacting their operations, and we’re thrilled to bring this industry-first capability into Explore to automate access for all our clients. With pathways ranging from low to high impact, this capability further enables organizations to grasp the full spectrum of potential outcomes in real-time, make informed decisions and proactively mitigate risks.”
According to New Orleans-based LongueVue, the “strategic rebranding” brings together the complementary capabilities of these three companies to form a vertically integrated flexible packaging leader with expertise in blown film production, flexographic printing, adhesive laminations, and converting.
“This unified platform enables us to provide our customers with greater flexibility and innovation across all aspects of packaging," Joe Piccione, CEO of Innotex, said in a release. "As we continue to evolve and adapt to the changing needs of the industry, we look forward to delivering exceptional solutions and service."
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Stampin’ Up!’s Riverton, Utah, distribution center
What happens when your warehouse technology upgrade turns into a complete process overhaul? That may sound like a headache to some, but for leaders at paper crafting company Stampin’ Up! it’s been a golden opportunity—especially when it comes to boosting productivity. The Utah-based direct marketing company has increased its average pick rate by more than 70% in the past year and a half. And it’s all due to a warehouse management system (WMS) implementation that opened the door to process changes and new technologies that are speeding its high-velocity, high-SKU (stock-keeping unit) order fulfillment operations.
The bottom line: Stampin’ Up! is filling orders faster than ever before, with less manpower, since it shifted to an easy-to-use voice picking system that makes adapting to seasonal product changes and promotions a piece of cake. Here’s how.
FACING UP TO CHANGE
Stampin’ Up!’s business increased rapidly in 2020, when pandemic-era lockdowns sparked a surge in online orders for its crafting and scrapbooking supplies—everything from rubber stamps to specialty papers, ink, and embellishments needed for home-based projects. At around the same time, company leaders learned that the WMS in use at its main distribution center (DC) in Riverton, Utah, was nearing its end-of-life and would have to be replaced. That process set in motion a series of changes that would upend the way Stampin’ Up! picked items and filled orders, setting the company on a path toward continuous improvement.
“We began a process to replace the WMS, with no intent to do anything else,” explains Rich Bushell, the company’s director of global distribution services. “But when we started to investigate a new WMS, we began to look at the larger picture. We saw problems within our [picking] system. Really, they were problems with our processes.”
Stampin’ Up! had hired global supply chain consulting firm Argon & Co. to help with the WMS selection and implementation, and it was that process that sparked the change. Argon & Co. Partner Steve Mulaik, who worked on the project, says it quickly became clear that Stampin’ Up!’s zone-based pick-and-pass fulfillment process wasn’t working well—primarily because pickers spent a lot of idle time waiting for the next order. Under the old system, which used pick-to-light technology, workers stood in their respective zones and made picks only from their assigned location; when it came time for a pick, the system directed them where to make that pick via indicator lights on storage shelves. The workers placed the picked items directly into shipping boxes that would be passed to the next zone via conveyor.
“The business problem here was that they had a system that didn’t work reliably,” Mulaik explains. “And there were periods when [workers] would have nothing to do. The workload was not balanced.”
This was less than ideal for a DC facing accelerating demand for multi-item orders—a typical Stampin’ Up! order contains 17 to 21 items per box, according to Bushell. In a bid to make the picking process more flexible, Mulaik suggested eliminating the zones altogether and changing the workflow. Ultimately, that would mean replacing the pick-to-light system and revamping the pick-and-pass process with a protocol that would keep workers moving and orders flowing consistently.
“We changed the whole process, building on some academic work from Georgia Tech along with how you communicate with the system,” Mulaik explains. “Together, that has really resulted in the significant change in productivity that they’ve seen.”
RIGHTING THE SHIP
The Riverton DC’s new solution combines voice picking technology with a whole new process known as “bucket brigade” picking. A bucket brigade helps distribute work more evenly among pickers in a DC: Pickers still work in a production-line fashion, picking items into bins or boxes and then sending the bins down the line via conveyor. But rather than stop and wait for the next order to come to them, pickers continue to work by walking up to the next person on the line and taking over that person’s assignment; the worker who is overtaken does the same, creating a process in which pickers are constantly filling orders and no one is picking from the same location.
Stampin’ Up! doesn’t follow the bucket brigade process precisely but has instead developed its own variation the company calls “leapfrog.” Instead of taking the next person’s work, pickers will move up the line to the next open order after completing a task—“leapfrogging” over the other pickers in the line to keep the process moving.
“We’re moving to the work,” Bushell explains. “If your boxes are full and you push them [down the line], you just move to the open work. The idea is that it takes the zones away; you move to where the next pick is.”
The voice piece increases the operation’s flexibility and directs the leapfrog process. Voice-directed picking allows pickers to listen to commands and respond verbally via a headset and handheld device. All commands filter through the headset, freeing the worker’s eyes and hands for picking tasks. Stampin’ Up! uses voice technology from AccuSpeechMobile with a combination of company-issued Android devices and Bluetooth headsets, although employees can use their own Bluetooth headsets or earbuds if they wish.
Mulaik and Bushell say the simplicity of the AccuSpeechMobile system was a game-changer for this project. The device-based system requires no voice server or middleware and no changes to a customer’s back-end systems in order to operate. It uses “screen scrape” technology, a process that allows the collection of large volumes of data quickly. Essentially, the program translates textual information from the device into audible commands telling associates what to pick. Workers then respond verbally, confirming the pick.
“AccuSpeech takes what the [WMS] says and then says it in your ear,” Bushell explains. “The key to the device is having all the data needed to make the pick shown on the screen. However, the picker should never—or rarely—need to look at the screen [because] the voice tells them the info and the commands are set up to repeat if prompted. This helps increase speed.
“The voice piece really ties everything together and makes our system more efficient.”
And about that system: Stampin’ Up! chose a WMS from technology provider QSSI, which directs all the work in the DC. And the conveyor systems were updated with new equipment and controls—from ABCO Systems and JR Controls—to keep all those orders moving down the line. The company also adopted automated labeling technology and overhauled its slotting procedure—the process of determining the most efficient storage location for its various items—as part of the project.
MISSION ACCOMPLISHED
Productivity improvement in the DC has been the biggest benefit of the project, which was officially completed in the spring of 2023 but continues to bear fruit. Prior to the change, Stampin’ Up! workers averaged 160 picks per hour, per person. That number rose to more than 200 picks per hour within the first few months, according to Bushell, and was up to 276 picks per hour as of this past August—a more than 70% increase.
“We’ve seen some really good gains,” Bushell says, adding that the company has reduced its reliance on both temporary and full-time staff as well, the latter mainly through attrition. “Overall, we’re 20% to 25% down on our labor based on the change …. And it’s because we’re keeping people busy.”
Quality has stayed on par as well, something Bushell says concerned him when switching from the DC’s previous pick-to-light technology.
“You have very good quality with pick-to-light, so we [worried] about opening the door to errors with pick-to-voice because a human is confirming each pick,” he says. “But we average about one error per 3,300 picks. So the quality is really good.”
On top of all that, Bushell says employees are “really happy” with the new system. One reason is that the voice system is easy to learn—so easy, anyone can do it. Stampin’ Up! runs frequent promotions and special offers that create mini spikes in business throughout the year; the new system makes it easy to get the required temporary help up to speed quickly or recruit staff members from other departments to accommodate those spikes.
“We [allocate] three days of training for voice, but it’s really about an hour,” Bushell says, adding that some of the employees from other departments simply enjoy the change of pace and the exercise of working on the “leapfrog” bucket brigade. “I have people that sign up every day to come pick.”
Not only has Stampin’ Up! reduced downtime and expedited the picking of its signature rubber stamps, paper, and crafting supplies, but it’s also blazing a trail in fulfillment that its business partners say could serve as a model for other companies looking to crank up productivity in the DC.
“There are a lot of [companies] that have pick-and-pass systems today, and while those pick-and-pass systems look like they are efficient, those companies may not realize that people are only picking 70% of the time,” Mulaik says. “This is a way to reduce that inactivity significantly.
“If you can get 20% of your productivity back—that’s a big number.”
With its new AutoStore automated storage and retrieval (AS/RS) system, Toyota Material Handling Inc.’s parts distribution center, located at its U.S. headquarters campus in Columbus, Indiana, will be able to store more forklift and other parts and move them more quickly. The new system represents a major step toward achieving TMH’s goal of next-day parts delivery to 98% of its customers in the U.S. and Canada by 2030, said TMH North America President and CEO Brett Wood at the launch event on October 28. The upgrade to the DC was designed, built, and installed through a close collaboration between TMH, AutoStore, and Bastian Solutions, the Toyota-owned material handling automation designer and systems integrator that is a cornerstone of the forklift maker’s Toyota Automated Logistics business unit. The AS/RS is Bastian’s 100th AutoStore installation in North America.
TMH’s AutoStore system deploys 28 energy-efficient robotic shuttles to retrieve and deliver totes from within a vertical storage grid. To expedite processing, artificial intelligence (AI)-enhanced software determines optimal storage locations based on whether parts are high- or low-demand items. The shuttles, each independently controlled and selected based on shortest distance to the stored tote, swiftly deliver the ordered parts to four picking ports. Each port can process up to 175 totes per hour; the company’s initial goal is 150 totes per hour, with room to grow. The AS/RS also eliminates the need for order pickers to walk up to 10 miles per day, saving time, boosting picking accuracy, and improving ergonomics for associates.
The upgrades, which also include a Kardex vertical lift module for parts that are too large for the AS/RS and a spiral conveyor, will more than triple storage capacity, from 40,000 to 128,000 storage positions, making it possible for TMH to increase its parts inventory. Currently the DC stores some 55,000 stock-keeping units (SKUs) and ships an average of $1 million worth of parts per day, reaching 80% of customers by two-day ground delivery. A Sparck Technologies CVP Impack fit-to-size packaging machine speeds packing and shipping and is expected to save up to 20% on the cost of packing materials.
Distribution, manufacturing expansion on the agenda
The Columbus parts DC currently serves all of the U.S. and Canada; inventory consists mostly of Toyota’s own parts as well as some parts for Bastian Solutions and forklift maker The Raymond Corp., which is part of TMH North America. To meet the company’s goal of next-day delivery to virtually all parts customers, TMH is exploring establishing up to five additional parts DCs. All will be TMH-designed, owned, and operated, with varying levels of automation to meet specific needs, said Bret Bruin, vice president, aftermarket sales and operations, in an interview.
Parts distribution is not the only area where TMH is investing in expanded capacity. With demand for electric forklifts continuing to rise, the company recently broke ground for a new factory on the expansive Columbus campus that will benefit both Toyota and Raymond. The two OEMs—which currently have only 5% overlap among their customers—already manufacture certain forklift models and parts for each other, said Wood in an interview. Slated to open in 2026, the $100 million, 295,000-square-foot factory will make electric-powered forklifts. The lineup will include stand-up rider trucks, currently manufactured for both brands by Raymond in Greene, New York. Moving production to Columbus, Wood said, will not only help both OEMs keep up with fast-growing demand for those models, but it will also free up space and personnel in Raymond’s factory to increase production of orderpickers and reach trucks, which it produces for both brands. “We want to build the right trucks in the right place,” Wood said.
Editor's note:This article was revised on November 4 to correct the types of equipment produced in Raymond's factory.
Parcel giant FedEx Corp. is automating its fulfillment flows by investing in the AI robotics and autonomous e-commerce fulfillment technology firm Nimble, and announcing plans to use the San Francisco-based startup’s tech in its own returns network.
The move is significant because FedEx Supply Chain operates at a large scale, running more than 130 warehouse and fulfillment operations in North America and processing 475 million returns annually. According to FedEx, the “strategic alliance” will help to scale up FedEx Fulfillment with Nimble’s “fully autonomous 3PL model.”
“Our strategic alliance and financial investment with Nimble expands our footprint in the e-commerce space, helping to further scale our FedEx Fulfillment offering across North America,” Scott Temple, president, FedEx Supply Chain, said in a release. “Nimble’s cutting-edge AI robotics and autonomous fulfillment systems will help FedEx streamline operations and unlock new opportunities for our customers.”
According to Nimble founder and CEO Simon Kalouche, the collaboration will help enable FedEx to leverage Nimble’s “fast and cost-effective” fulfillment centers, powered by its intelligent general purpose warehouse robots and AI technology.
Nimble says that more than 90% of warehouses today still operate manually with minimal or no robotics, and even those automated warehouses use robots with limited intelligence that are restricted to just a few warehouse functions—primarily storage and retrieval. In contrast, Nimble says its “intelligent general-purpose warehouse robot” is capable of performing all core fulfillment functions including storage and retrieval, picking, packing, and sorting.