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 distribution was one of the hottest trends in the retail sector this year, with companies across the industry rushing to combine their e-commerce fulfillment operations with those for brick-and-mortar store sales.
Retailers have adopted a wide variety of approaches when it comes to omnichannel fulfillment. Some fill orders placed by online customers by pulling items directly from retail shelves, others run separate fulfillment operations for e-commerce and store replenishment orders, while still others combine these operations, using a single DC to fulfill e-commerce orders, replenish retail stores, and ship wholesale orders.
Despite success stories at companies like clothing retailer Abercrombie & Fitch and department store chain Dillard's Inc., not all omnichannel operations are revenue rockets. In fact, many companies struggle to run their omnichannel operations at a profit.
"Omnichannel is absolutely being done, although it's taking up lots of resources and probably not being done as profitably as many of us would like," said Jason Denmon, apparel and specialty retail industry leader at the distribution consulting and design engineering firm Fortna Inc. So what can retailers do to change that? We asked some experts for their advice.
TARGET YOUR EFFORTS
The first step in fine-tuning an omnichannel operation so that it runs more profitably is to identify which fulfillment flow the company wants to optimize, Denmon said. No single company can do it all, so it helps to target investment in one place, such as tracking truck routes within its own fleet, choosing a reliable third-party logistics (3PL) partner, or shipping parcels with an overnight carrier.
"Some firms do 'buy online, pick up from store'; some do 'buy online, ship from store.' You need to monitor whichever fulfillment flow you're using, and go back and optimize that," said Denmon.
For example, some retailers offer free shipping for home goods and bulky items ordered online if the customer is willing to pick them up from the store. Such a retailer might save money on omnichannel operations if it adjusted its truck routes to make sure each shipment leaving the warehouse was a full truckload.
THERE'S NO SUCH THING AS FREE SHIPPING
A second crucial step for boosting the profitability of your omnichannel operation is to set realistic shipping fees.
That can be difficult in a market where online retailers compete for customers by offering free shipping or next-day delivery. But companies that sell $10 items can seldom make a profit shipping one or two units to an online buyer's home. Shipping costs will simply wipe out their profit margins.
That's led some retailers to adopt a more nuanced, choice-based approach. "The more progressive retailers have changed their website designs to communicate options to customers and give them choices," Denmon said. "For example, you can have it shipped for free and wait three to five days, or you can upgrade and get it tomorrow. They let the customer choose what speed is worth."
A variation on that scenario has been playing out in the U.K., where some online grocers have begun charging a fee for their "click and collect" programs, where online shoppers place food orders at home, then pick them up in person at the nearest supermarket.
However, that model has met with some resistance. The grocers are simply charging for their picking and packing services, but many customers have been outraged because they've become accustomed to free shipping, said David Jefferys, global market leader for e-commerce and omnichannel at KUKA Swisslog.
"Same-day service is a race to the bottom," Jefferys said. "The service level has to increase with a cost. There's no win-win that leads to an increase in service level without an increase in cost."
OUTSOURCING OMNICHANNEL OPERATIONS
Many retailers have been paying for shipping all along, whether they charge their e-commerce customers or not. But that means they have to find some way to offset that hidden cost. A number of brick-and-mortar retailers have used funds from other departments to subsidize the cost of building out their omnichannel fulfillment operations, Jefferys said. That accounting may work fine for the launch, but as e-commerce begins to account for a larger share of total revenue, the operation becomes more expensive and tougher to justify.
Faced with that reality, many companies have chosen to outsource their e-commerce fulfillment to a major third-party logistics service provider (3PL) such as DHL International, said Jefferys. Huge retailers like Amazon.com Inc. and Alibaba.com can afford to run their own distribution channels, but most of the smaller players need help with transportation and warehousing.
But even the major retailers are likely to face challenges when it comes to building a homegrown omnichannel operation. For example, there's the question of where to locate their operations. A company that builds a DC dedicated to e-commerce must decide whether it needs to provide one- or two-day delivery to customers' homes. That decision may affect whether it picks a warehouse located near Louisville, Ky., or Memphis, Tenn., depending on whether they're a UPS Inc. or a FedEx Corp. shop, said Marc Wulfraat, president of the Montreal-based consulting firm MWPVL International Inc.
Another challenge in building a successful omnichannel operation is balancing the demands of e-commerce with those of retail store operations. The primary function of physical storefronts is to serve as a showroom for the company's products and to allow sales associates to build relationships with customers. But a situation where workers are pulling inventory off store shelves even as live shoppers try to fill their carts is hardly conducive to relationship building. "Let's say a guy grabs the last box of your favorite cereal and he's wearing a Wal-Mart uniform," said Wulfraat. Chances are, the in-store shopper will be left feeling that the company values the e-commerce customer's business more than his or her own.
In addition to potentially offending shoppers, some retailers find that fulfilling e-commerce orders from stores is simply inefficient, Wulfraat said. Store employees may find that it takes much longer to pick and pack specific items in a hectic retail environment than in a well-ordered warehouse.
Despite the challenges, big national retailers such as Macy's Inc., Target Brands Inc., and Wal-Mart continue to fill orders from stores, he said, setting the standard for running an omnichannel operation and keeping the pressure on their competitors.
As for what the future holds, it's anybody's guess. As a recent survey made clear (see "Study: Omnichannel retailers still fine-tuning fulfillment operations" in this issue), there are just two universal truths when it comes to omnichannel distribution: each company is adapting to the omnichannel challenge in its own way, and the future will continue to bring changes in fulfillment strategies and practices.
Congestion on U.S. highways is costing the trucking industry big, according to research from the American Transportation Research Institute (ATRI), released today.
The group found that traffic congestion on U.S. highways added $108.8 billion in costs to the trucking industry in 2022, a record high. The information comes from ATRI’s Cost of Congestion study, which is part of the organization’s ongoing highway performance measurement research.
Total hours of congestion fell slightly compared to 2021 due to softening freight market conditions, but the cost of operating a truck increased at a much higher rate, according to the research. As a result, the overall cost of congestion increased by 15% year-over-year—a level equivalent to more than 430,000 commercial truck drivers sitting idle for one work year and an average cost of $7,588 for every registered combination truck.
The analysis also identified metropolitan delays and related impacts, showing that the top 10 most-congested states each experienced added costs of more than $8 billion. That list was led by Texas, at $9.17 billion in added costs; California, at $8.77 billion; and Florida, $8.44 billion. Rounding out the top 10 list were New York, Georgia, New Jersey, Illinois, Pennsylvania, Louisiana, and Tennessee. Combined, the top 10 states account for more than half of the trucking industry’s congestion costs nationwide—52%, according to the research.
The metro areas with the highest congestion costs include New York City, $6.68 billion; Miami, $3.2 billion; and Chicago, $3.14 billion.
ATRI’s analysis also found that the trucking industry wasted more than 6.4 billion gallons of diesel fuel in 2022 due to congestion, resulting in additional fuel costs of $32.1 billion.
ATRI used a combination of data sources, including its truck GPS database and Operational Costs study benchmarks, to calculate the impacts of trucking delays on major U.S. roadways.
There’s a photo from 1971 that John Kent, professor of supply chain management at the University of Arkansas, likes to show. It’s of a shaggy-haired 18-year-old named Glenn Cowan grinning at three-time world table tennis champion Zhuang Zedong, while holding a silk tapestry Zhuang had just given him. Cowan was a member of the U.S. table tennis team who participated in the 1971 World Table Tennis Championships in Nagoya, Japan. Story has it that one morning, he overslept and missed his bus to the tournament and had to hitch a ride with the Chinese national team and met and connected with Zhuang.
Cowan and Zhuang’s interaction led to an invitation for the U.S. team to visit China. At the time, the two countries were just beginning to emerge from a 20-year period of decidedly frosty relations, strict travel bans, and trade restrictions. The highly publicized trip signaled a willingness on both sides to renew relations and launched the term “pingpong diplomacy.”
Kent, who is a senior fellow at the George H. W. Bush Foundation for U.S.-China Relations, believes the photograph is a good reminder that some 50-odd years ago, the economies of the United States and China were not as tightly interwoven as they are today. At the time, the Nixon administration was looking to form closer political and economic ties between the two countries in hopes of reducing chances of future conflict (and to weaken alliances among Communist countries).
The signals coming out of Washington and Beijing are now, of course, much different than they were in the early 1970s. Instead of advocating for better relations, political rhetoric focuses on the need for the U.S. to “decouple” from China. Both Republicans and Democrats have warned that the U.S. economy is too dependent on goods manufactured in China. They see this dependency as a threat to economic strength, American jobs, supply chain resiliency, and national security.
Supply chain professionals, however, know that extricating ourselves from our reliance on Chinese manufacturing is easier said than done. Many pundits push for a “China + 1” strategy, where companies diversify their manufacturing and sourcing options beyond China. But in reality, that “plus one” is often a Chinese company operating in a different country or a non-Chinese manufacturer that is still heavily dependent on material or subcomponents made in China.
This is the problem when supply chain decisions are made on a global scale without input from supply chain professionals. In an article in the Arkansas Democrat-Gazette, Kent argues that, “The discussions on supply chains mainly take place between government officials who typically bring many other competing issues and agendas to the table. Corporate entities—the individuals and companies directly impacted by supply chains—tend to be under-represented in the conversation.”
Kent is a proponent of what he calls “supply chain diplomacy,” where experts from academia and industry from the U.S. and China work collaboratively to create better, more efficient global supply chains. Take, for example, the “Peace Beans” project that Kent is involved with. This project, jointly formed by Zhejiang University and the Bush China Foundation, proposes balancing supply chains by exporting soybeans from Arkansas to tofu producers in China’s Yunnan province, and, in return, importing coffee beans grown in Yunnan to coffee roasters in Arkansas. Kent believes the operation could even use the same transportation equipment.
The benefits of working collaboratively—instead of continuing to build friction in the supply chain through tariffs and adversarial relationships—are numerous, according to Kent and his colleagues. They believe it would be much better if the two major world economies worked together on issues like global inflation, climate change, and artificial intelligence.
And such relations could play a significant role in strengthening world peace, particularly in light of ongoing tensions over Taiwan. Because, as Kent writes, “The 19th-century idea that ‘When goods don’t cross borders, soldiers will’ is as true today as ever. Perhaps more so.”
Hyster-Yale Materials Handling today announced its plans to fulfill the domestic manufacturing requirements of the Build America, Buy America (BABA) Act for certain portions of its lineup of forklift trucks and container handling equipment.
That means the Greenville, North Carolina-based company now plans to expand its existing American manufacturing with a targeted set of high-capacity models, including electric options, that align with the needs of infrastructure projects subject to BABA requirements. The company’s plans include determining the optimal production location in the United States, strategically expanding sourcing agreements to meet local material requirements, and further developing electric power options for high-capacity equipment.
As a part of the 2021 Infrastructure Investment and Jobs Act, the BABA Act aims to increase the use of American-made materials in federally funded infrastructure projects across the U.S., Hyster-Yale says. It was enacted as part of a broader effort to boost domestic manufacturing and economic growth, and mandates that federal dollars allocated to infrastructure – such as roads, bridges, ports and public transit systems – must prioritize materials produced in the USA, including critical items like steel, iron and various construction materials.
Hyster-Yale’s footprint in the U.S. is spread across 10 locations, including three manufacturing facilities.
“Our leadership is fully invested in meeting the needs of businesses that require BABA-compliant material handling solutions,” Tony Salgado, Hyster-Yale’s chief operating officer, said in a release. “We are working to partner with our key domestic suppliers, as well as identifying how best to leverage our own American manufacturing footprint to deliver a competitive solution for our customers and stakeholders. But beyond mere compliance, and in line with the many areas of our business where we are evolving to better support our customers, our commitment remains steadfast. We are dedicated to delivering industry-leading standards in design, durability and performance — qualities that have become synonymous with our brands worldwide and that our customers have come to rely on and expect.”
In a separate move, the U.S. Environmental Protection Agency (EPA) also gave its approval for the state to advance its Heavy-Duty Omnibus Rule, which is crafted to significantly reduce smog-forming nitrogen oxide (NOx) emissions from new heavy-duty, diesel-powered trucks.
Both rules are intended to deliver health benefits to California citizens affected by vehicle pollution, according to the environmental group Earthjustice. If the state gets federal approval for the final steps to become law, the rules mean that cars on the road in California will largely be zero-emissions a generation from now in the 2050s, accounting for the average vehicle lifespan of vehicles with internal combustion engine (ICE) power sold before that 2035 date.
“This might read like checking a bureaucratic box, but EPA’s approval is a critical step forward in protecting our lungs from pollution and our wallets from the expenses of combustion fuels,” Paul Cort, director of Earthjustice’s Right To Zero campaign, said in a release. “The gradual shift in car sales to zero-emissions models will cut smog and household costs while growing California’s clean energy workforce. Cutting truck pollution will help clear our skies of smog. EPA should now approve the remaining authorization requests from California to allow the state to clean its air and protect its residents.”
However, the truck drivers' industry group Owner-Operator Independent Drivers Association (OOIDA) pushed back against the federal decision allowing the Omnibus Low-NOx rule to advance. "The Omnibus Low-NOx waiver for California calls into question the policymaking process under the Biden administration's EPA. Purposefully injecting uncertainty into a $588 billion American industry is bad for our economy and makes no meaningful progress towards purported environmental goals," (OOIDA) President Todd Spencer said in a release. "EPA's credibility outside of radical environmental circles would have been better served by working with regulated industries rather than ramming through last-minute special interest favors. We look forward to working with the Trump administration's EPA in good faith towards achievable environmental outcomes.”
Editor's note:This article was revised on December 18 to add reaction from OOIDA.
A Canadian startup that provides AI-powered logistics solutions has gained $5.5 million in seed funding to support its concept of creating a digital platform for global trade, according to Toronto-based Starboard.
The round was led by Eclipse, with participation from previous backers Garuda Ventures and Everywhere Ventures. The firm says it will use its new backing to expand its engineering team in Toronto and accelerate its AI-driven product development to simplify supply chain complexities.
According to Starboard, the logistics industry is under immense pressure to adapt to the growing complexity of global trade, which has hit recent hurdles such as the strike at U.S. east and gulf coast ports. That situation calls for innovative solutions to streamline operations and reduce costs for operators.
As a potential solution, Starboard offers its flagship product, which it defines as an AI-based transportation management system (TMS) and rate management system that helps mid-sized freight forwarders operate more efficiently and win more business. More broadly, Starboard says it is building the virtual infrastructure for global trade, allowing freight companies to leverage AI and machine learning to optimize operations such as processing shipments in real time, reconciling invoices, and following up on payments.
"This investment is a pivotal step in our mission to unlock the power of AI for our customers," said Sumeet Trehan, Co-Founder and CEO of Starboard. "Global trade has long been plagued by inefficiencies that drive up costs and reduce competitiveness. Our platform is designed to empower SMB freight forwarders—the backbone of more than $20 trillion in global trade and $1 trillion in logistics spend—with the tools they need to thrive in this complex ecosystem."