Mark Solomon joined DC VELOCITY as senior editor in August 2008, and was promoted to his current position on January 1, 2015. He has spent more than 30 years in the transportation, logistics and supply chain management fields as a journalist and public relations professional. From 1989 to 1994, he worked in Washington as a reporter for the Journal of Commerce, covering the aviation and trucking industries, the Department of Transportation, Congress and the U.S. Supreme Court. Prior to that, he worked for Traffic World for seven years in a similar role. From 1994 to 2008, Mr. Solomon ran Media-Based Solutions, a public relations firm based in Atlanta. He graduated in 1978 with a B.A. in journalism from The American University in Washington, D.C.
Amazon.com Inc. never arrives in towns empty-handed. Whether it be pre-payment of 95 percent of employee tuition to pursue careers in high-growth industries, classroom training within its fulfillment centers, benefits that start on the first day of employment, or 20 weeks of paid maternity leave, the Seattle-based e-tailing giant will do whatever's needed to grab qualified DC labor.
This "PacMan" gobble-up strategy is a necessity given Amazon's fulfillment center growth. It plans to add 45 distribution or fulfillment centers in the U.S. alone over the next two years, according to estimates from MWPVL Inc., a consultancy that tracks Amazon. As of June, Amazon operated 244 U.S. facilities, 105 of those being DCs or fulfillment centers, MWPVL said.
Amazon said in January it planned to hire 100,000 full-time employees by mid-2018, a goal it expects to achieve given what it sees as strong and sustainable application activity. According to MWPVL, Amazon currently employs an estimated 127,000 full-time and at least 54,000 seasonal workers, although the consultancy believes the seasonal labor force may be much higher than that. Notoriously tight-lipped Amazon declined an interview request for this story.
Amazon's wage rates will vary depending on conditions in specific markets. It has said that while it believes it pays competitive wages, the true value of its compensation package lies in the numerous ancillary benefits. It is consistently in the top quartile of payers, according to ProLogistix, a division of Atlanta-based EmployBridge that specializes in warehouse and DC staffing.
Amazon's expansion, combined with a pickup in fulfillment demand from the growth of e-commerce and a multidecade low in overall U.S. unemployment, has been responsible for a $1.70-an-hour jump in DC worker wages since 2011 to $12.13 an hour, according to ProLogistix. (Wages during the peak fulfillment month of December have risen at a faster clip.) While that may not seem like much, it should be noted that worker wages increased a puny 15 cents an hour from 2002 to 2012, according to ProLogistix data. In some markets, Amazon will pay up to $2 an hour more than other warehouse and DC employers.
In an annual warehouse employee opinion poll conducted among DC workers who are ProLogistix employees, 59 percent said they are now making $12 an hour or more, up from 26 percent in 2014. Of employees who changed jobs for higher pay, around 30 percent said their new job paid more than $2 an hour above their previous one. In some cases, hourly increases are approaching $3, according to Brian Devine, ProLogistix's president.
Amazon's facilities are often clustered near competitors' locations, which can put pressure on labor cost and availability because multiple companies are drawing from the same labor pool, Devine said. Michael Mikitka, chief executive officer of the Warehousing Education and Research Council (WERC), said some members have told him of shrinking labor availability in the markets where Amazon opens a facility.
Amazon's growth has created a ripple effect as well. The Raymond Corp., a Greene, N.Y.-based forklift manufacturer and a big Amazon supplier, is increasingly relying on its dealership network to support busy in-house technicians in providing repair and maintenance services, according to Jim O'Brien, Raymond's vice president of telematics. Part of that can be attributed to Amazon's growth and the demands it puts on fulfillment center vendors like Raymond, O'Brien said. Overall, however, Raymond's labor challenges have been moderate but not severe.
WHAT'S THE PROBLEM?
It's a given that Amazon influences the ebb and flow of warehouse and DC labor. The question is to what degree. While the official U.S. unemployment rate hovers around 4.2 percent, there are still around 95 million people over the age of 16 who, for one reason or another, are not in the work force, said Devine of ProLogistix, citing U.S. Department of Labor data. Being able to utilize even a fraction of that number could alleviate labor strains in the warehouse, he said.
The key would be for warehouse managers to adjust their time-honored practices, whether it means relaxing time-off requirements, staggering worker schedules, or, in the case of older workers, accepting the reality that they move a little slower, Devine said. "There is enough labor out there. Just not in the traditional sense," he said.
Mikitka of WERC said the same people who described wage and availability concerns when Amazon builds a facility also said that, if a market is tight enough, any company can alter the supply-demand balance simply by entering it.
The consensus is that current labor conditions would be tight even if Amazon didn't exist. That's because as big as Amazon has become, it does not dominate an $18 trillion economy. O'Brien of Raymond posits that if Amazon weren't around to capitalize on e-commerce's potential, another company would have done so, noting that U.S. consumer trends were ripe for the type of revolution under way today.
At the same time, however, there is a sense that Amazon isn't doling out any pain that it isn't bringing on itself through its rapid growth. "Right now, finding labor is the single biggest challenge across the board for everyone, and especially [for] Amazon," said Marc Wulfraat, president of MWPVL.
If a labor shortage and the higher costs that accompany it persist, folks shouldn't count on a shift to automation to provide substantial relief. Amazon itself has said that its objective is not to use automation to replace its work force, but to supplement it by freeing humans to handle more value-added functions. Devine of ProLogistix, who has long held the view that it would be virtually impossible for technology to substitute for the aggregate value of so many workers, echoed that sentiment. "What we will see automation do is make people more accurate and productive in their work," he said.
Devine said he doesn't foresee any time within the next decade where warehouse automation will make a dent in the continued need for human labor.
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]."