Study: omnichannel retailers still fine-tuning fulfillment operations
As they grapple with the logistics challenges that omnichannel brings, retailers continue to tweak their operations—whether that means adopting tried-and-true technologies or experimenting with drones.
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.
Omnichannel commerce is one of the most powerful trends to sweep through the retail world in recent years.
In search of more efficient ways to control the flow of inventory, companies in nearly every corner of the retail industry are experimenting with various distribution strategies, whether it's filling both e-commerce and store replenishment orders from a single DC, running separate fulfillment operations, or filling online orders directly from brick-and-mortar store shelves.
But building a fast and profitable omnichannel fulfillment system can challenge every department in a company, from supply chain management to IT, marketing, store operations, and order fulfillment.
To get a better understanding of how companies are meeting the challenges of omnichannel distribution, DC Velocity and ARC Advisory Group, a management consulting firm in Dedham, Mass., teamed up to conduct our third annual survey on retail fulfillment practices. Respondents answered about 40 questions on their approaches to meeting current challenges in omnichannel commerce and their plans for the future.
The results show that companies are moving toward omnichannel operations with a goal of gaining customers and boosting revenue. Asked to list the top three reasons their company was participating in omnichannel commerce or building up those capabilities, survey respondents appeared to be squarely focused on revenue, saying they did it to increase sales (57 percent), increase market share (56 percent), and improve customer loyalty (55 percent).
Although our survey respondents clearly shared a common goal, that's where the commonality ended. The research results also showed that they used a wide variety of strategies and methods when it came to their omnichannel distribution practices.
THE MECHANICS OF OMNICHANNEL DISTRIBUTION
When we asked how they fulfilled e-commerce orders, the respondents' answers were all over the map: 63 percent said orders were fulfilled through a traditional DC that also handles e-commerce, 47 percent used a Web-only DC, 43 percent fulfilled orders from the store, and 36 percent said e-commerce orders were filled directly from the manufacturer or supplier. Respondents were allowed to select more than one response, and as the percentages indicate, a number of those companies are using multiple methods. (See Exhibit 1.)
Likewise, asked whether they handled e-commerce fulfillment at the same facility where they conducted traditional fulfillment operations, 69 percent of survey respondents said yes, with 31 percent saying no. (See Exhibit 2.)
Some of the companies engaged in omnichannel distribution have opted to outsource the entire operation, hiring a third-party logistics service provider (3PL) to handle the fulfillment end of their e-commerce operations. Survey takers were fairly evenly divided in their responses to questions about their strategies. The results showed that 55 percent relied on their own corporate (internally managed) distribution centers, while 22 percent only used sites operated by their outsourcing partners. Another 23 percent said they are taking a combined approach.
Within the warehouse, workers are using a wide variety of tools and methods to select items needed to fill e-commerce orders. Survey respondents said order pickers in distribution centers were using the following technologies: warehouse management systems (WMS) combined with radio frequency technology (53 percent), voice-recognition systems (33 percent), pick-to-light technology (22 percent), paper-based WMS (35 percent), and goods-to-person automation (20 percent).
Their managers also use a range of tools to support omnichannel commerce initiatives. When we asked respondents what technologies they used, the top three answers were high-end warehouse management systems (91 percent), demand management software (72 percent), and basic bar-code scanning on the store floor or in the backroom (61 percent). (See Exhibit 3.)
DELIVERING THE GOODS
A crucial link in any omnichannel fulfillment operation is the final step: getting e-commerce orders into customers' hands. Here, the options range from in-store pickup to home delivery. We drilled into current practices in this area as well as respondents' plans for the future. What we found was that e-commerce delivery is an area that's very much in flux.
The responses to our first question—"How do you handle 'last mile' deliveries?"—contained few surprises. The most popular answers were courier delivery services such as FedEx and UPS (84 percent), drop shipping directly from partners' DCs (61 percent), a 3PL delivery partner (50 percent), and store fleet (40 percent). (See Exhibit 4.)
It was a different story altogether when it came to respondents' plans for the future. When we asked which shipping methods they "Do not use, but plan to use," their responses pointed in some interesting directions. For instance, they showed particular interest in crowdsourced delivery services such as Deliv or Instacart (0 percent use them today, 28 percent plan to use them); store staff delivery via car, bike, or foot (21 percent use them today, 13 percent plan to use them); and even drones (0 percent use them today, 2 percent plan to use them).
MEANWHILE, BACK AT THE STORE ...
Of course, one of the more distinctive aspects of omnichannel commerce is that many purchases are never processed or shipped from warehouses at all, but are handled directly through retail stores.
To better understand how retail outlets fit into the picture, we asked survey respondents which fulfillment-related activities they carried out at their store locations. Sixty-eight percent of the respondents who fill at least some orders from stores said e-commerce orders were both picked and shipped from the store, while 64 percent said the orders were picked at the store and then held for customer pickup. A smaller percentage—47 percent—said they shipped e-commerce orders from a DC to the store for customer pickup.
That raised another issue: whether the retailers' employees picked the items from the stockroom or the showroom. The responses were pretty evenly divided, with 71 percent saying they picked orders from the back of the store and 64 percent from the front.
Finally, we dug even deeper, asking what methods stores used to communicate order information to the workers who picked those orders. The answers showed that stores lag well behind warehouses and DCs when it comes to the adoption of fulfillment technology, since the most popular reply was the paper-based method, with 56 percent. Trailing far behind were radio-frequency (RF) gun with textual display (26 percent), RF gun with graphical display (also 26 percent), and some other mobile device (15 percent).
THE ECONOMICS OF OMNICHANNEL
Despite the rapid growth of omnichannel commerce, our survey also revealed that e-commerce revenue has a long way to go before it eclipses brick-and-mortar sales income.
We asked survey respondents what percentage of their direct retail revenue—revenue from items sold to consumers through their own sales platforms, as opposed to being moderated by a retail partner—currently came from each channel. The average for brick and mortar was 63 percent, far above online and mobile (24 percent), and call center and catalog (15 percent). (See Exhibit 5.)
Despite the modest revenue generated through online, mobile, call center, and catalog sales, a solid majority of respondents had sales operations up and running in every channel. When asked to list all the channels in which they currently receive direct retail orders, respondents cited online (84 percent), brick and mortar (76 percent), call center and catalog (57 percent), and mobile (46 percent).
Taken together, the survey results indicate that omnichannel retailing is here to stay, but that fulfillment practices remain in flux. In particular, our study points to changes ahead in the area of parcel delivery. Stay tuned for next year's survey, when we track the further progress of these trends that are revolutionizing the industry.
About the study
This year's omnichannel study was conducted by ARC Advisory Group in conjunction with DC Velocity. ARC analyst Chris Cunnane oversaw the research and compiled the results. The 2015 study builds on research done last year in this area, which found that significant opportunity gaps exist among companies from a technology deployment standpoint.
This year's study explored the details of DC operations to support omnichannel initiatives, as well as how companies are handling the last-mile dilemma. The findings reported here are based on 120 responses.
As for the demographic breakdown, the majority of respondents (57 percent) sold goods through a combination of direct and indirect sales channels. Another 31 percent sold through direct retail only, and the remaining 12 percent through indirect sales channels only.
A report containing a more detailed examination of the omnichannel survey results is available from ARC for a fee. For information, visit www.arcweb.com/research.
Editor's Note: This story has been updated to correct some of the numbers in the survey results. The changes do not affect the conclusions drawn in the article.
Autonomous forklift maker Cyngn is deploying its DriveMod Tugger model at COATS Company, the largest full-line wheel service equipment manufacturer in North America, the companies said today.
By delivering the self-driving tuggers to COATS’ 150,000+ square foot manufacturing facility in La Vergne, Tennessee, Cyngn said it would enable COATS to enhance efficiency by automating the delivery of wheel service components from its production lines.
“Cyngn’s self-driving tugger was the perfect solution to support our strategy of advancing automation and incorporating scalable technology seamlessly into our operations,” Steve Bergmeyer, Continuous Improvement and Quality Manager at COATS, said in a release. “With its high load capacity, we can concentrate on increasing our ability to manage heavier components and bulk orders, driving greater efficiency, reducing costs, and accelerating delivery timelines.”
Terms of the deal were not disclosed, but it follows another deployment of DriveMod Tuggers with electric automaker Rivian earlier this year.
Manufacturing and logistics workers are raising a red flag over workplace quality issues according to industry research released this week.
A comparative study of more than 4,000 workers from the United States, the United Kingdom, and Australia found that manufacturing and logistics workers say they have seen colleagues reduce the quality of their work and not follow processes in the workplace over the past year, with rates exceeding the overall average by 11% and 8%, respectively.
The study—the Resilience Nation report—was commissioned by UK-based regulatory and compliance software company Ideagen, and it polled workers in industries such as energy, aviation, healthcare, and financial services. The results “explore the major threats and macroeconomic factors affecting people today, providing perspectives on resilience across global landscapes,” according to the authors.
According to the study, 41% of manufacturing and logistics workers said they’d witnessed their peers hiding mistakes, and 45% said they’ve observed coworkers cutting corners due to apathy—9% above the average. The results also showed that workers are seeing colleagues take safety risks: More than a third of respondents said they’ve seen people putting themselves in physical danger at work.
The authors said growing pressure inside and outside of the workplace are to blame for the lack of diligence and resiliency on the job. Internally, workers say they are under pressure to deliver more despite reduced capacity. Among the external pressures, respondents cited the rising cost of living as the biggest problem (39%), closely followed by inflation rates, supply chain challenges, and energy prices.
“People are being asked to deliver more at work when their resilience is being challenged by economic and political headwinds,” Ideagen’s CEO Ben Dorks said in a statement announcing the findings. “Ultimately, this is having a determinantal impact on business productivity, workplace health and safety, and the quality of work produced, as well as further reducing the resilience of the nation at large.”
Respondents said they believe technology will eventually alleviate some of the stress occurring in manufacturing and logistics, however.
“People are optimistic that emerging tech and AI will ultimately lighten the load, but they’re not yet feeling the benefits,” Dorks added. “It’s a gap that now, more than ever, business leaders must look to close and support their workforce to ensure their staff remain safe and compliance needs are met across the business.”
The “2024 Year in Review” report lists the various transportation delays, freight volume restrictions, and infrastructure repair costs of a long string of events. Those disruptions include labor strikes at Canadian ports and postal sites, the U.S. East and Gulf coast port strike; hurricanes Helene, Francine, and Milton; the Francis Scott key Bridge collapse in Baltimore Harbor; the CrowdStrike cyber attack; and Red Sea missile attacks on passing cargo ships.
“While 2024 was characterized by frequent and overlapping disruptions that exposed many supply chain vulnerabilities, it was also a year of resilience,” the Project44 report said. “From labor strikes and natural disasters to geopolitical tensions, each event served as a critical learning opportunity, underscoring the necessity for robust contingency planning, effective labor relations, and durable infrastructure. As supply chains continue to evolve, the lessons learned this past year highlight the increased importance of proactive measures and collaborative efforts. These strategies are essential to fostering stability and adaptability in a world where unpredictability is becoming the norm.”
In addition to tallying the supply chain impact of those events, the report also made four broad predictions for trends in 2025 that may affect logistics operations. In Project44’s analysis, they include:
More technology and automation will be introduced into supply chains, particularly ports. This will help make operations more efficient but also increase the risk of cybersecurity attacks and service interruptions due to glitches and bugs. This could also add tensions among the labor pool and unions, who do not want jobs to be replaced with automation.
The new administration in the United States introduces a lot of uncertainty, with talks of major tariffs for numerous countries as well as talks of US freight getting preferential treatment through the Panama Canal. If these things do come to fruition, expect to see shifts in global trade patterns and sourcing.
Natural disasters will continue to become more frequent and more severe, as exhibited by the wildfires in Los Angeles and the winter storms throughout the southern states in the U.S. As a result, expect companies to invest more heavily in sustainability to mitigate climate change.
The peace treaty announced on Wednesday between Isael and Hamas in the Middle East could support increased freight volumes returning to the Suez Canal as political crisis in the area are resolved.
The French transportation visibility provider Shippeo today said it has raised $30 million in financial backing, saying the money will support its accelerated expansion across North America and APAC, while driving enhancements to its “Real-Time Transportation Visibility Platform” product.
The funding round was led by Woven Capital, Toyota’s growth fund, with participation from existing investors: Battery Ventures, Partech, NGP Capital, Bpifrance Digital Venture, LFX Venture Partners, Shift4Good and Yamaha Motor Ventures. With this round, Shippeo’s total funding exceeds $140 million.
Shippeo says it offers real-time shipment tracking across all transport modes, helping companies create sustainable, resilient supply chains. Its platform enables users to reduce logistics-related carbon emissions by making informed trade-offs between modes and carriers based on carbon footprint data.
"Global supply chains are facing unprecedented complexity, and real-time transport visibility is essential for building resilience” Prashant Bothra, Principal at Woven Capital, who is joining the Shippeo board, said in a release. “Shippeo’s platform empowers businesses to proactively address disruptions by transforming fragmented operations into streamlined, data-driven processes across all transport modes, offering precise tracking and predictive ETAs at scale—capabilities that would be resource-intensive to develop in-house. We are excited to support Shippeo’s journey to accelerate digitization while enhancing cost efficiency, planning accuracy, and customer experience across the supply chain.”
Donald Trump has been clear that he plans to hit the ground running after his inauguration on January 20, launching ambitious plans that could have significant repercussions for global supply chains.
As Mark Baxa, CSCMP president and CEO, says in the executive forward to the white paper, the incoming Trump Administration and a majority Republican congress are “poised to reshape trade policies, regulatory frameworks, and the very fabric of how we approach global commerce.”
The paper is written by import/export expert Thomas Cook, managing director for Blue Tiger International, a U.S.-based supply chain management consulting company that focuses on international trade. Cook is the former CEO of American River International in New York and Apex Global Logistics Supply Chain Operation in Los Angeles and has written 19 books on global trade.
In the paper, Cook, of course, takes a close look at tariff implications and new trade deals, emphasizing that Trump will seek revisions that will favor U.S. businesses and encourage manufacturing to return to the U.S. The paper, however, also looks beyond global trade to addresses topics such as Trump’s tougher stance on immigration and the possibility of mass deportations, greater support of Israel in the Middle East, proposals for increased energy production and mining, and intent to end the war in the Ukraine.
In general, Cook believes that many of the administration’s new policies will be beneficial to the overall economy. He does warn, however, that some policies will be disruptive and add risk and cost to global supply chains.
In light of those risks and possible disruptions, Cook’s paper offers 14 recommendations. Some of which include:
Create a team responsible for studying the changes Trump will introduce when he takes office;
Attend trade shows and make connections with vendors, suppliers, and service providers who can help you navigate those changes;
Consider becoming C-TPAT (Customs-Trade Partnership Against Terrorism) certified to help mitigate potential import/export issues;
Adopt a risk management mindset and shift from focusing on lowest cost to best value for your spend;
Increase collaboration with internal and external partners;
Expect warehousing costs to rise in the short term as companies look to bring in foreign-made goods ahead of tariffs;
Expect greater scrutiny from U.S. Customs and Border Patrol of origin statements for imports in recognition of attempts by some Chinese manufacturers to evade U.S. import policies;
Reduce dependency on China for sourcing; and
Consider manufacturing and/or sourcing in the United States.
Cook advises readers to expect a loosening up of regulations and a reduction in government under Trump. He warns that while some world leaders will look to work with Trump, others will take more of a defiant stance. As a result, companies should expect to see retaliatory tariffs and duties on exports.
Cook concludes by offering advice to the incoming administration, including being sensitive to the effect retaliatory tariffs can have on American exports, working on federal debt reduction, and considering promoting free trade zones. He also proposes an ambitious water works program through the Army Corps of Engineers.