At its new dietary supplement plant, Amway needed a way to move goods in and out of cleanrooms while limiting human touches. The answer? Automated guided vehicles.
David Maloney has been a journalist for more than 35 years and is currently the group editorial director for DC Velocity and Supply Chain Quarterly magazines. In this role, he is responsible for the editorial content of both brands of Agile Business Media. Dave joined DC Velocity in April of 2004. Prior to that, he was a senior editor for Modern Materials Handling magazine. Dave also has extensive experience as a broadcast journalist. Before writing for supply chain publications, he was a journalist, television producer and director in Pittsburgh. Dave combines a background of reporting on logistics with his video production experience to bring new opportunities to DC Velocity readers, including web videos highlighting top distribution and logistics facilities, webcasts and other cross-media projects. He continues to live and work in the Pittsburgh area.
As one of the world's largest direct-sales consumer businesses, Amway knows that the quality of its products is paramount to its success. That's why in an age when many companies outsource production, Amway chooses to manufacture a significant amount of its own health and beauty products, even growing some of the plants that will be used as ingredients on its own organic farms.
That can be a challenge. The manufacture of supplements and cosmetics is governed by a host of federal laws and regulations. Amway must follow the Food and Drug Administration's (FDA) current Good Manufacturing Practices (cGMP) regulations, which specify how ingredients for these products are handled, stored, and used in manufacturing. Among many other things, the cGMP regulations require that production be performed in sanitary manufacturing environments.
All that had to be factored into the planning when Amway began work on a project to convert a former warehouse building into a new manufacturing plant for its Nutrilite soft gel dietary supplements. That building, known as the Spaulding facility, is located in Ada, Mich., about three miles from company headquarters, where many of Amway's goods are manufactured (the company offers some 450 different products in all). The new manufacturing operation, which opened in 2014, has allowed the company to increase production of the soft gels. On top of that, the facility's proximity to the company's other manufacturing sites has created opportunities for distribution economies of scale.
Though Spaulding had been a distribution center in its previous life, the Amway team started with a clean slate in designing the new manufacturing operation. Among other considerations, it would have to find a way to accommodate multiple activities with very different operating requirements under the same roof. Production, for example, would have to be performed in a sanitary manufacturing environment, while many of the manufacturing support functions, like receiving, storage, and shipping, could not possibly maintain the same levels of sanitation. That meant that areas would have to be set aside for these activities apart from the manufacturing cells.
One of the most challenging parts of the design was figuring out how to move products easily from these functional areas into the clean environment s without slowing down production or contaminating the processing areas. Because contamination is often transmitted through people, limiting human touches was an important part of the solution.
"We wanted to prevent having people moving back and forth between the warehouse and the manufacturing area because each time they would enter manufacturing, they'd be required to gown-up," says Dave DeVries, principal engineer.
To minimize human involvement, Amway invested in a fleet of five automated guided vehicles (AGVs) from material handling and logistics systems provider Dematic. The AGVs handle most of the intraplant material moves, taking products in and out of storage and ferrying them to manufacturing areas. Although there are some limits to where they may go in the facility—for instance, the AGVs do not venture into any areas where raw materials are processed or into rooms with open product containers—they're still able to handle much of the intraplant transport work.
Dematic also implemented a warehouse execution system (WES) to manage the flow of goods as well as an integrated equipment management system (EMS) to control the AGVs' movement. Working with Dematic is convenient for Amway, as Dematic's North American operations are based in nearby Grand Rapids. In fact, the two companies have worked together on many projects in the past.
LEAN AND CLEAN
The quality control process that guides every aspect of the work at Spaulding starts in receiving. As ingredients for the supplements—like gelatin, glycerin, and fish oils—arrive at the facility's 10 truck docks, workers load the drums, boxes, and sacks onto plastic pallets supplied by Gorilla Pallets. Plastic pallets were chosen both for reasons of hygiene and because they have the consistent dimensions required for use with AGVs.
Two forklifts (supplied by UniCarriers) gather the pallet loads from the docks for transport to a receiving rack system that holds 52 pallets—about the number contained in one incoming truckload. The rack serves as a transfer point between the dock and the warehouse, with all forklift traffic restricted to the dock side while the AGVs operate on the other side. The receiving rack is one pallet position deep and four levels high, and is accessible from both sides.
The forklift operator first locates an open rack position. He then scans the pallet ID and a rack location bar code to assign the pallet to a particular slot. The scans automatically notify the WES of the products' temporary location.
The forklift operator then places the load into the rack position. Mechanical guides built into the racks assure that the pallets are placed precisely into the slots. That makes it easier for the AGVs to retrieve the loads from the opposite side of the racking.
The WES coordinates with the EMS to control the AGVs. It uses a "look for work" algorithm, whereby the software matches an AGV with a task based on the vehicle's location, status, and availability. When an item is needed, the WES assigns the selected AGV to retrieve the pallet from the receiving rack. Each AGV's forks are able to reach up to 18 feet high, so the units can easily access any of the pallet positions within the four-level racks.
The laser-guided AGVs navigate using a rotating sensor attached to the top of each vehicle. "The vehicles look for reflectors mounted at locations within the building," explains DeVries. "The AGVs follow designated fixed paths, though we have the ability to change some paths."
Two other laser sensors (supplied by sensor manufacturer Sick) also check for obstacles and will stop the AGV if they detect a person or object in its path. They even "look" around corners as they approach a turn to make certain the route is clear. DeVries reports that the safety features have worked flawlessly, noting that all workers in the facility have also been trained to be aware of AGVs working nearby.
After a pallet load has been retrieved from the receiving racks, the WES assigns it to one of the building's internal warehouses for storage. Like other parts of the building, the warehouses have specific classification levels according to what is stored inside and the specific activities they support.
The warehouses are further divided according to the attributes of the ingredients they house and thus, vary according to temperature, humidity, or other storage-related considerations. Some oils, for example, require a temperature-controlled environment, so these are stored in a separate area where the proper environment can be maintained. In accordance with storage requirements, care is also taken to segregate allergens from other materials and products.
The AGV carries the pallet to the assigned warehouse and deposits the load into the proper location in the storage racks, which, like the receiving racks, are four levels high. The amount of time a given product spends in storage varies by ingredient. To keep items fresh, the facility manages inventory by expiration date, sending items with the earliest expiration dates to manufacturing first.
For recordkeeping purposes, the EMS that operates the AGVs also records and tracks the inventory moves, passing the location data along to the WES that manages the warehouse and tracks all activities in real time.
THE RIGHT INGREDIENTS
Workers in the manufacturing areas control the delivery of ingredients to the production areas. When an ingredient is needed, a worker uses a computer to access the operator interface within the EMS and call for the material. The management software then dispatches an AGV to the appropriate warehouse to retrieve the ingredient.
In keeping with the FDA cGMP regulations, the facility is designed with vestibules that provide a clean buffer zone between the warehouses and the various manufacturing areas. As an AGV approaches a vestibule, it signals (via an RF antenna) an automatic door to roll up to give the vehicle access to the vestibule (the automatic doors were supplied by Rytec). The first door closes and a second door opens to allow the AGV to exit to dedicated drop zones adjacent to the manufacturing cells, where the AGV deposits the load.
There are, however, some manufacturing areas where the guidelines prohibit AGVs from entering. At these locations, the AGV simply drops its load in the vestibule and departs via the same door through which it entered. An operator working in the manufacturing area then opens the second door to retrieve the load with a pallet jack.
Once inside the manufacturing area, a worker removes the ingredients from the pallet for use in production. If more than one pallet of a given ingredient is needed, the worker uses a wireless push button to signal the EMS that he or she is ready for delivery of the next pallet.
When all of the ingredients have been consumed, the operator takes the empty plastic pallet and places it onto a stack. When a full stack is accumulated, the operator signals the EMS to send an AGV to gather and transport the empties to an automated pallet washer. If unused ingredients remain on a pallet, an AGV is summoned to return it to its warehouse.
The AGVs also handle pallet moves for work-in-process. After manufacturing and inspection, palletized boxes of bulk soft gels are moved to a packaging staging warehouse, which is a small storage area that is temperature- and humidity-controlled. This area contains four levels of racking for temporary storage of the bulk soft gels. The AGVs later collect the gels for packaging internally or for shipment to another Nutrilite facility for final packaging.
When a truck arrives for pickup, AGVs are again summoned to retrieve the loads from the finished-goods warehouse. After the loads are secured for transport (using Lantech stretch wrappers), the AGVs deliver them to floor staging lanes, where manual forklifts take over the loading of pallets onto the truck.
SAFE AND SOUND
As for how it has all worked out, since moving to the Dematic AGVs, Amway has accomplished its goals of maintaining a clear separation between the warehouse and production. Plus, there's no more waiting around for forklift drivers to deliver goods, as workers can simply call for the AGVs to deliver products on demand.
Dematic continues to provide ongoing support for the AGVs. "We had a great working relationship with Dematic from the design phase through commissioning, and they continue to do our quarterly preventive maintenance and the training of our technicians who maintain our systems daily," says DeVries.
Eliminating forklift traffic and congestion in production areas has also resulted in a safe manufacturing environment. It further allows Amway to allocate its work force to production instead of intraplant transport. And best of all, Amway has gained the "supplemental" advantages of consistency and accuracy in its operations.
Nearly one-third of American consumers have increased their secondhand purchases in the past year, revealing a jump in “recommerce” according to a buyer survey from ShipStation, a provider of web-based shipping and order fulfillment solutions.
The number comes from a survey of 500 U.S. consumers showing that nearly one in four (23%) Americans lack confidence in making purchases over $200 in the next six months. Due to economic uncertainty, savvy shoppers are looking for ways to save money without sacrificing quality or style, the research found.
Younger shoppers are leading the charge in that trend, with 59% of Gen Z and 48% of Millennials buying pre-owned items weekly or monthly. That rate makes Gen Z nearly twice as likely to buy second hand compared to older generations.
The primary reason that shoppers say they have increased their recommerce habits is lower prices (74%), followed by the thrill of finding unique or rare items (38%) and getting higher quality for a lower price (28%). Only 14% of Americans cite environmental concerns as a primary reason they shop second-hand.
Despite the challenge of adjusting to the new pattern, recommerce represents a strategic opportunity for businesses to capture today’s budget-minded shoppers and foster long-term loyalty, Austin, Texas-based ShipStation said.
For example, retailers don’t have to sell used goods to capitalize on the secondhand boom. Instead, they can offer trade-in programs swapping discounts or store credit for shoppers’ old items. And they can improve product discoverability to help customers—particularly older generations—find what they’re looking for.
Other ways for retailers to connect with recommerce shoppers are to improve shipping practices. According to ShipStation:
70% of shoppers won’t return to a brand if shipping is too expensive.
51% of consumers are turned off by late deliveries
40% of shoppers won’t return to a retailer again if the packaging is bad.
The “CMA CGM Startup Awards”—created in collaboration with BFM Business and La Tribune—will identify the best innovations to accelerate its transformation, the French company said.
Specifically, the company will select the best startup among the applicants, with clear industry transformation objectives focused on environmental performance, competitiveness, and quality of life at work in each of the three areas:
Shipping: Enabling safer, more efficient, and sustainable navigation through innovative technological solutions.
Logistics: Reinventing the global supply chain with smart and sustainable logistics solutions.
Media: Transform content creation, and customer engagement with innovative media technologies and strategies.
Three winners will be selected during a final event organized on November 15 at the Orange Vélodrome Stadium in Marseille, during the 2nd Artificial Intelligence Marseille (AIM) forum organized by La Tribune and BFM Business. The selection will be made by a jury chaired by Rodolphe Saadé, Chairman and CEO of the Group, and including members of the executive committee representing the various sectors of CMA CGM.
The global air cargo market’s hot summer of double-digit demand growth continued in August with average spot rates showing their largest year-on-year jump with a 24% increase, according to the latest weekly analysis by Xeneta.
Xeneta cited two reasons to explain the increase. First, Global average air cargo spot rates reached $2.68 per kg in August due to continuing supply and demand imbalance. That came as August's global cargo supply grew at its slowest ratio in 2024 to-date at 2% year-on-year, while global cargo demand continued its double-digit growth, rising +11%.
The second reason for higher rates was an ocean-to-air shift in freight volumes due to Red Sea disruptions and e-commerce demand.
Those factors could soon be amplified as e-commerce shows continued strong growth approaching the hotly anticipated winter peak season. E-commerce and low-value goods exports from China in the first seven months of 2024 increased 30% year-on-year, including shipments to Europe and the US rising 38% and 30% growth respectively, Xeneta said.
“Typically, air cargo market performance in August tends to follow the July trend. But another month of double-digit demand growth and the strongest rate growths of the year means there was definitely no summer slack season in 2024,” Niall van de Wouw, Xeneta’s chief airfreight officer, said in a release.
“Rates we saw bottoming out in late July started picking up again in mid-August. This is too short a period to call a season. This has been a busy summer, and now we’re at the threshold of Q4, it will be interesting to see what will happen and if all the anticipation of a red-hot peak season materializes,” van de Wouw said.
The report cites data showing that there are approximately 1.7 million workers missing from the post-pandemic workforce and that 38% of small firms are unable to fill open positions. At the same time, the “skills gap” in the workforce is accelerating as automation and AI create significant shifts in how work is performed.
That information comes from the “2024 Labor Day Report” released by Littler’s Workplace Policy Institute (WPI), the firm’s government relations and public policy arm.
“We continue to see a labor shortage and an urgent need to upskill the current workforce to adapt to the new world of work,” said Michael Lotito, Littler shareholder and co-chair of WPI. “As corporate executives and business leaders look to the future, they are focused on realizing the many benefits of AI to streamline operations and guide strategic decision-making, while cultivating a talent pipeline that can support this growth.”
But while the need is clear, solutions may be complicated by public policy changes such as the upcoming U.S. general election and the proliferation of employment-related legislation at the state and local levels amid Congressional gridlock.
“We are heading into a contentious election that has already proven to be unpredictable and is poised to create even more uncertainty for employers, no matter the outcome,” Shannon Meade, WPI’s executive director, said in a release. “At the same time, the growing patchwork of state and local requirements across the U.S. is exacerbating compliance challenges for companies. That, coupled with looming changes following several Supreme Court decisions that have the potential to upend rulemaking, gives C-suite executives much to contend with in planning their workforce-related strategies.”
Stax Engineering, the venture-backed startup that provides smokestack emissions reduction services for maritime ships, will service all vessels from Toyota Motor North America Inc. visiting the Toyota Berth at the Port of Long Beach, according to a new five-year deal announced today.
Beginning in 2025 to coincide with new California Air Resources Board (CARB) standards, STAX will become the first and only emissions control provider to service roll-on/roll-off (ro-ros) vessels in the state of California, the company said.
Stax has rapidly grown since its launch in the first quarter of this year, supported in part by a $40 million funding round from investors, announced in July. It now holds exclusive service agreements at California ports including Los Angeles, Long Beach, Hueneme, Benicia, Richmond, and Oakland. The firm has also partnered with individual companies like NYK Line, Hyundai GLOVIS, Equilon Enterprises LLC d/b/a Shell Oil Products US (Shell), and now Toyota.
Stax says it offers an alternative to shore power with land- and barge-based, mobile emissions capture and control technology for shipping terminal and fleet operators without the need for retrofits.
In the case of this latest deal, the Toyota Long Beach Vehicle Distribution Center imports about 200,000 vehicles each year on ro-ro vessels. Stax will keep those ships green with its flexible exhaust capture system, which attaches to all vessel classes without modification to remove 99% of emitted particulate matter (PM) and 95% of emitted oxides of nitrogen (NOx). Over the lifetime of this new agreement with Toyota, Stax estimated the service will account for approximately 3,700 hours and more than 47 tons of emissions controlled.
“We set out to provide an emissions capture and control solution that was reliable, easily accessible, and cost-effective. As we begin to service Toyota, we’re confident that we can meet the needs of the full breadth of the maritime industry, furthering our impact on the local air quality, public health, and environment,” Mike Walker, CEO of Stax, said in a release. “Continuing to establish strong partnerships will help build momentum for and trust in our technology as we expand beyond the state of California.”