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.
Progress in generative AI (GenAI) is poised to impact business procurement processes through advancements in three areas—agentic reasoning, multimodality, and AI agents—according to Gartner Inc.
Those functions will redefine how procurement operates and significantly impact the agendas of chief procurement officers (CPOs). And 72% of procurement leaders are already prioritizing the integration of GenAI into their strategies, thus highlighting the recognition of its potential to drive significant improvements in efficiency and effectiveness, Gartner found in a survey conducted in July, 2024, with 258 global respondents.
Gartner defined the new functions as follows:
Agentic reasoning in GenAI allows for advanced decision-making processes that mimic human-like cognition. This capability will enable procurement functions to leverage GenAI to analyze complex scenarios and make informed decisions with greater accuracy and speed.
Multimodality refers to the ability of GenAI to process and integrate multiple forms of data, such as text, images, and audio. This will make GenAI more intuitively consumable to users and enhance procurement's ability to gather and analyze diverse information sources, leading to more comprehensive insights and better-informed strategies.
AI agents are autonomous systems that can perform tasks and make decisions on behalf of human operators. In procurement, these agents will automate procurement tasks and activities, freeing up human resources to focus on strategic initiatives, complex problem-solving and edge cases.
As CPOs look to maximize the value of GenAI in procurement, the study recommended three starting points: double down on data governance, develop and incorporate privacy standards into contracts, and increase procurement thresholds.
“These advancements will usher procurement into an era where the distance between ideas, insights, and actions will shorten rapidly,” Ryan Polk, senior director analyst in Gartner’s Supply Chain practice, said in a release. "Procurement leaders who build their foundation now through a focus on data quality, privacy and risk management have the potential to reap new levels of productivity and strategic value from the technology."
Businesses are cautiously optimistic as peak holiday shipping season draws near, with many anticipating year-over-year sales increases as they continue to battle challenging supply chain conditions.
That’s according to the DHL 2024 Peak Season Shipping Survey, released today by express shipping service provider DHL Express U.S. The company surveyed small and medium-sized enterprises (SMEs) to gauge their holiday business outlook compared to last year and found that a mix of optimism and “strategic caution” prevail ahead of this year’s peak.
Nearly half (48%) of the SMEs surveyed said they expect higher holiday sales compared to 2023, while 44% said they expect sales to remain on par with last year, and just 8% said they foresee a decline. Respondents said the main challenges to hitting those goals are supply chain problems (35%), inflation and fluctuating consumer demand (34%), staffing (16%), and inventory challenges (14%).
But respondents said they have strategies in place to tackle those issues. Many said they began preparing for holiday season earlier this year—with 45% saying they started planning in Q2 or earlier, up from 39% last year. Other strategies include expanding into international markets (35%) and leveraging holiday discounts (32%).
Sixty percent of respondents said they will prioritize personalized customer service as a way to enhance customer interactions and loyalty this year. Still others said they will invest in enhanced web and mobile experiences (23%) and eco-friendly practices (13%) to draw customers this holiday season.
That challenge is one of the reasons that fewer shoppers overall are satisfied with their shopping experiences lately, Lincolnshire, Illinois-based Zebra said in its “17th Annual Global Shopper Study.”th Annual Global Shopper Study.” While 85% of shoppers last year were satisfied with both the in-store and online experiences, only 81% in 2024 are satisfied with the in-store experience and just 79% with online shopping.
In response, most retailers (78%) say they are investing in technology tools that can help both frontline workers and those watching operations from behind the scenes to minimize theft and loss, Zebra said.
Just 38% of retailers currently use AI-based prescriptive analytics for loss prevention, but a much larger 50% say they plan to use it in the next 1-3 years. That was followed by self-checkout cameras and sensors (45%), computer vision (46%), and RFID tags and readers (42%) that are planned for use within the next three years, specifically for loss prevention.
Those strategies could help improve the brick and mortar shopping experience, since 78% of shoppers say it’s annoying when products are locked up or secured within cases. Adding to that frustration is that it’s hard to find an associate while shopping in stores these days, according to 70% of consumers. In response, some just walk out; one in five shoppers has left a store without getting what they needed because a retail associate wasn’t available to help, an increase over the past two years.
The survey also identified additional frustrations faced by retailers and associates:
challenges with offering easy options for click-and-collect or returns, despite high shopper demand for them
the struggle to confirm current inventory and pricing
lingering labor shortages and increasing loss incidents, even as shoppers return to stores
“Many retailers are laying the groundwork to build a modern store experience,” Matt Guiste, Global Retail Technology Strategist, Zebra Technologies, said in a release. “They are investing in mobile and intelligent automation technologies to help inform operational decisions and enable associates to do the things that keep shoppers happy.”
The survey was administered online by Azure Knowledge Corporation and included 4,200 adult shoppers (age 18+), decision-makers, and associates, who replied to questions about the topics of shopper experience, device and technology usage, and delivery and fulfillment in store and online.
An eight-year veteran of the Georgia company, Hakala will begin his new role on January 1, when the current CEO, Tero Peltomäki, will retire after a long and noteworthy career, continuing as a member of the board of directors, Cimcorp said.
According to Hakala, automation is an inevitable course in Cimcorp’s core sectors, and the company’s end-to-end capabilities will be crucial for clients’ success. In the past, both the tire and grocery retail industries have automated individual machines and parts of their operations. In recent years, automation has spread throughout the facilities, as companies want to be able to see their entire operation with one look, utilize analytics, optimize processes, and lead with data.
“Cimcorp has always grown by starting small in the new business segments. We’ve created one solution first, and as we’ve gained more knowledge of our clients’ challenges, we have been able to expand,” Hakala said in a release. “In every phase, we aim to bring our experience to the table and even challenge the client’s initial perspective. We are interested in what our client does and how it could be done better and more efficiently.”
Although many shoppers will
return to physical stores this holiday season, online shopping remains a driving force behind peak-season shipping challenges, especially when it comes to the last mile. Consumers still want fast, free shipping if they can get it—without any delays or disruptions to their holiday deliveries.
One disruptor that gets a lot of headlines this time of year is package theft—committed by so-called “porch pirates.” These are thieves who snatch parcels from front stairs, side porches, and driveways in neighborhoods across the country. The problem adds up to billions of dollars in stolen merchandise each year—not to mention headaches for shippers, parcel delivery companies, and, of course, consumers.
Given the scope of the problem, it’s no wonder online shoppers are worried about it—especially during holiday season. In its annual report on package theft trends, released in October, the
security-focused research and product review firm Security.org found that:
17% of Americans had a package stolen in the past three months, with the typical stolen parcel worth about $50. Some 44% said they’d had a package taken at some point in their life.
Package thieves poached more than $8 billion in merchandise over the past year.
18% of adults said they’d had a package stolen that contained a gift for someone else.
Ahead of the holiday season, 88% of adults said they were worried about theft of online purchases, with more than a quarter saying they were “extremely” or “very” concerned.
But it doesn’t have to be that way. There are some low-tech steps consumers can take to help guard against porch piracy along with some high-tech logistics-focused innovations in the pipeline that can protect deliveries in the last mile. First, some common-sense advice on avoiding package theft from the Security.org research:
Install a doorbell camera, which is a relatively low-cost deterrent.
Bring packages inside promptly or arrange to have them delivered to a secure location if no one will be at home.
Consider using click-and-collect options when possible.
If the retailer allows you to specify delivery-time windows, consider doing so to avoid having packages sit outside for extended periods.
These steps may sound basic, but they are by no means a given: Fewer than half of Americans consider the timing of deliveries, less than a third have a doorbell camera, and nearly one-fifth take no precautions to prevent package theft, according to the research.
Tech vendors are stepping up to help. One example is
Arrive AI, which develops smart mailboxes for last-mile delivery and pickup. The company says its Mailbox-as-a-Service (MaaS) platform will revolutionize the last mile by building a network of parcel-storage boxes that can be accessed by people, drones, or robots. In a nutshell: Packages are placed into a weatherproof box via drone, robot, driverless carrier, or traditional delivery method—and no one other than the rightful owner can access it.
Although the platform is still in development, the company already offers solutions for business clients looking to secure high-value deliveries and sensitive shipments. The health-care industry is one example: Arrive AI offers secure drone delivery of medical supplies, prescriptions, lab samples, and the like to hospitals and other health-care facilities. The platform provides real-time tracking, chain-of-custody controls, and theft-prevention features. Arrive is conducting short-term deployments between logistics companies and health-care partners now, according to a company spokesperson.
The MaaS solution has a pretty high cool factor. And the common-sense best practices just seem like solid advice. Maybe combining both is the key to a more secure last mile—during peak shipping season and throughout the year as well.