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.
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]."