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.
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]."