The world may be buzzing about how robotics will revolutionize the warehouse, but for distribution and logistics managers, it can be hard to know where to start.
Hyster Co. provided one example of an entry point for companies looking to "stick their toe into robotics" at this year's Modex show. The forklift company demonstrated its robotic lift truck solution, which adds robotic capabilities to existing Hyster forklift trucks. The tower on the back of the lift truck is wired with a camera and sensors that allow the truck to work without a driver for those 10 to 20 percent of actions that are routine and repetitive.
One example would be an application where an operator accompanies the robotic lift truck during the picking process. Once the order has been completely picked and human assistance is no longer required, the lift truck would drive itself over to the dock. Meanwhile, another robotic vehicle would automatically be sent to work with the operator. (Hyster Co., www.hyster.com)
Forklift reader:
Venture Research Inc., a global supplier of RFID (radio-frequency identification) and IoT (Internet of Things) solutions, has unveiled an "intelligent" industrial forklift reader. Designed to autonomously manage a pick, drop, stack, and move operation using an array of RFID and IoT sensors, the new reader can withstand both indoor and outdoor harsh environments, the company says. With the swappable rechargeable lithium-ion battery, the reader can be quickly installed to full operation in just five minutes on a standard type 2 or type 3 carriage forklift.
The forklift reader can sense its environment and autonomously manage the complete pick/drop/stack operation while providing store and forward transactions directly to the cloud via Wi-Fi or optional cellular communications. Built-in location tracking that incorporates GPS, RFID, and IoT (BLE) provides positional awareness of the forklift in real time.
Available options include support of up to eight additional antennas, a front-facing camera, flexible power options, and vehicle-mount terminal (VMT) support. (Venture Research Inc., www.ventureresearch.com)
Specialized lift truck forks: Lift truck attachment company Cascade Corp. has unveiled a new line of specialized forks. Known as "Forks+," the line consists of weigh, telescopic, and roller platen forks.
The weigh forks automatically weigh and display the weight of pallet loads of up to 10,000 pounds. The weight information can also be communicated to the user's warehouse management system (WMS).
Telescopic forks, or hydraulic fork extensions, allow lift trucks to load or unload trailers and trains from the side or allow a standard lift truck to be used in place of a reach truck.
The roller platen forks consist of wide forks with built-in rollers that allow the lift truck to handle slipsheets, cartons, or sacks. The forks include a braking mechanism that keeps the load from rolling off the forks. (Cascade Corp., www.cascorp.com)
Order pickers: Toyota Forklifts has introduced three new order pickers. The new models feature Toyota's optional Lift Logic Speed and Height Control System, which enables fast and easy picking, the company says. The line includes Toyota's first model in the class to offer a 36-volt option with a reach height of up to 390 inches.
The three new models come equipped with AC drive, and two models come standard with AC lift. The entry-level model is a 24-volt that lifts up to 240 inches. The mid-level model is also a 24-volt and lifts up to 366 inches with faster lift speeds than competitive 24-volt models, the manufacturer says. The premium-level model is a 36-volt and lifts up to 390 inches.
The new order pickers are designed for use in the general warehousing, distribution, general manufacturing, retail, food storage, and cold storage industries. (Toyota Forklifts, www.toyotaforklift.com)
Forklift caster wheels: For companies tired of spending hours and money to replace caster wheels on their forklifts, Caster Concepts has come up with a solution: heavy-duty maintenance-free casters. Maintenance-free casters have precision neoprene-sealed ball bearings and hardened raceways, ensuring smooth rotation for several years. The kingpin-less design and thick forged steel can withstand shock loading and side forces, the company says.
The maintenance-free heavy-duty casters are built to handle loads of up to 3,500 pounds and reduce the amount of force needed to get them rolling, according to the manufacturer. The casters are also available in shock-absorbing formats for use as stabilizer casters on electric pallet trucks. (Caster Concepts, www.casterconcepts.com)
Zone lights:
To alert pedestrians to the presence of a forklift, Larson Electronics offers LED zone lights in red and blue, as well as LED strobe lamps. The company's forklift safety lighting units operate on low voltage and come with flexible mounting components, such as magnetic mounts, brackets, and clamps. These features enable forklift operators to secure the lights on racks and frames.
When the forklift is in operation, the unit projects a thick red or blue beam on the ground, warning pedestrians of the vehicle's presence. The LED strobe and zone lights can be combined with audible alarms, horns, and other notification devices for a comprehensive approach to operational safety, the company says. (Larson Electronics, www.larsonelectronics.com)
Pallet truck with Li-ion battery: The Raymond Corp. has introduced the Model 8250 AC walkie pallet truck with 24-volt 156 ampere-hour light EV battery pack. Built specifically for the Raymond Model 8250, this double-power-capacity lithium-ion (Li-ion) battery pack has been UL 2271 listed.
The Model 8250 with Li-ion battery provides CAN (controller area network) communication that allows data exchange between the truck and battery pack, providing operator feedback in the form of fault codes displayed on the truck's control handle as well as audible and visual alarms if charge is required or low.
The onboard battery management system allows the user to schedule charge times, provides notifications when charging is required, and monitors charging and usage to prevent overcharging and discharging events.
As an added benefit, the power pack includes integrated heaters for superior cold storage needs and thermal controls that reduce the risk of damage caused by environmental extremes. The power pack has been designed to handle rugged environments and is IP65-sealed and maintenance-free. In addition, Raymond's user interface offers the operator a visual representation of the battery's charge state.
The Raymond Model 8250 AC walkie pallet truck with Li-ion battery pack is also available in a standard configuration of 24-volt, 78 ampere-hour light EV battery pack. (The Raymond Corp., www.raymondcorp.com)
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]."