Mitch Mac Donald has more than 30 years of experience in both the newspaper and magazine businesses. He has covered the logistics and supply chain fields since 1988. Twice named one of the Top 10 Business Journalists in the U.S., he has served in a multitude of editorial and publishing roles. The leading force behind the launch of Supply Chain Management Review, he was that brand's founding publisher and editorial director from 1997 to 2000. Additionally, he has served as news editor, chief editor, publisher and editorial director of Logistics Management, as well as publisher of Modern Materials Handling. Mitch is also the president and CEO of Agile Business Media, LLC, the parent company of DC VELOCITY and CSCMP's Supply Chain Quarterly.
As a college student, Craig Weiss was attracted to logistics because of the problem-solving opportunities it offered. By that measure, the profession has clearly delivered on its promise. In the 20 years since Weiss entered the field, the logistics world has been rocked by a technology revolution, regulatory upheaval, and an epic trucking capacity crunch, to name just a few of the challenges.
Weiss has had a front-row view of the turmoil. For the past 16 years, he has held supply chain leadership positions with the Chicago-based packaged-foods giant Conagra Brands, whose portfolio includes such household names as Hunt's, Healthy Choice, Duncan Hines, Birds Eye, and Bertolli. Today, he is the company's senior vice president, supply chain, responsible for the full gamut of supply chain planning functions as well as transportation and warehousing.
Prior to joining Conagra Brands, Weiss held managerial roles at third-party logistics service providers ODW Logistics and Total Logistic Control (now part of Ryder), and served as a consultant at Ernst & Young. He spoke recently with DC Velocity Group Editorial Director Mitch Mac Donald about the shifting tech landscape, the supply chain of the future, and what keeps him up at night.
Q: Let's start with your career migration. How did you end up in the supply chain profession?
A: Actually, I got a degree in logistics in college. A professor of mine [at Central Michigan University], Dr. Robert Cook, convinced me that logistics was a great field to go into, and that if you like a fast-paced environment with opportunities to resolve operational challenges and work with people, logistics would be a great career choice. That is ultimately what helped guide me into a career in logistics.
Q: Could you tell us a little about the operations you oversee?
A: My current role at Conagra is leading the back end of our supply chain, meaning I oversee our supply chain planning functions, which includes demand planning as well as supply and inventory replenishment planning. I also lead Conagra's logistics team, which is transportation and warehousing, and our customer supply chain team, which is our strategic interface with our customers. I'm involved in several other initiatives as well, including our corporate enterprisewide productivity program and our DC network optimization program.
Q: What are some of the biggest challenges you face in today's market? That is, what keeps you up at night?
A: There are a couple of things that keep me up at night. Number one is the speed at which the supply chain and our customer's expectations are evolving and the challenges of staying relevant and competing in that fast-changing world.
Another, more tactical, challenge is how to enhance the efficiency of our freight-handling operations. The trucking capacity challenges of the past few years have really forced us to look at our distribution centers and examine our traditional notions about how long it should take to turn a truck around. We're now looking at ways to speed up the loading/unloading process and move trucks through our yards faster—including the possible use of some sort of advance reservation system.
We've set some pretty aggressive goals for improving the speed at which trucks can get in and out of our facilities.
Q: Turning to your distribution and fulfillment centers, are they internally staffed, outsourced to a third-party service provider (3PL), or a combination of the two?
A: It's a combination. We operate a number of our own distribution centers, and we also partner with some of the industry's leading 3PLs.
Q: One of the questions that often come up with 3PLs is how to maintain oversight of their operations and ensure that you're working toward the same objectives. How do you handle that?
A: I think it starts with having good strategic alignment of the two organizations, in finding ways to ensure that what's good for Conagra is also good for our third parties and vice versa. We want to be seen as a strategic customer with our third parties, so we go out of our way to ensure that they understand not only what we're doing in distribution but also what we're doing as a company.
We regularly bring our third parties in to discuss our growth plans, our customers' expectations, and our cost pressures. We include them as part of our staff meetings and truly operate as though they were an extension of our organization.
Q: Turning to your own DCs, are you having difficulty finding the labor and talent you need, and if so, how are you addressing that?
A: It can be challenging to find good, qualified people, especially for the more technical roles in some of our rural locations. We are constantly in search of the next great way to attract, retain, and develop talented people.
We have found that our teams are most effective when we create the right work environment for them and provide the right tools to succeed. This includes giving teams the freedom to own their work and results by promoting independent decision-making and eliminating bureaucracy, as well as ensuring that they are both accountable for their results and recognized for their contributions.
We also put a lot of emphasis on modernizing our processes, including investing in the right technology to help bring it all together.
Q: You provided a nice segue into another topic I wanted to touch on with you, which is technology. What are some of the technologies you're using to manage your DC and fulfillment operations?
A: I think we have a great track record at Conagra of leveraging technology to stay competitive in today's world. We use a suite of best-of-breed technology solutions to manage our supply chain operations. And we are constantly looking for new opportunities we can take advantage of, whether it is cloud computing, artificial intelligence, or predictive analytics solutions.
Q: Are there some technologies on the horizon that you think hold a lot of promise for your operations?
A: Yes, one example would be technologies like sensors that have the potential to provide true end-to-end visibility across the supply chain—visibility that in the past was sometimes hard to get.
Another area is automation—distribution center automation not just for e-commerce operations but also for facilities that are still shipping a combination of traditional truckloads, full pallet loads, and e-commerce orders. We are looking to take advantage of that both internally and with our third parties.
Q: Let's talk about the future. If you were to come to work tomorrow and it was Q4 2029 rather than 2019, what would look different to you?
A: The future of how food will be purchased and delivered will be very different, and as a result, I think that the forward-thinking nature of our operations will be very different. We will be focused on more predictive analytics of events that will occur months in the future—largely because we'll have access to cross-functional operations data that will enable us to foresee potential constraints and obstacles, and then respond to them.
The folks doing that will work across a broader swath of the supply chain. As the lines between transportation planning, inventory planning, and warehouse planning begin to blur, I think we will have fewer people in functional roles and more in cross-functional roles who will have a better understanding of the implications of their decisions.
Q: What should supply chain organizations be doing now to prepare for the future you just described?
A: Get the right people, with the right skills, and with the right structure, and then make the right investments in processes and technology to meet the goals of the company and its customers. Structurally, work to merge supply chain disciplines with analytic disciplines. Recruit people who not only have good operations skills and want to work with the products but also bring that analytical skill set. When you bring the operational and the analytic together, I think that is where you have your future supply chain.
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]."
First, 54% of retailers are looking for ways to increase their financial recovery from returns. That’s because the cost to return a purchase averages 27% of the purchase price, which erases as much as 50% of the sales margin. But consumers have their own interests in mind: 76% of shoppers admit they’ve embellished or exaggerated the return reason to avoid a fee, a 39% increase from 2023 to 204.
Second, return experiences matter to consumers. A whopping 80% of shoppers stopped shopping at a retailer because of changes to the return policy—a 34% increase YoY.
Third, returns fraud and abuse is top-of-mind-for retailers, with wardrobing rising 38% in 2024. In fact, over two thirds (69%) of shoppers admit to wardrobing, which is the practice of buying an item for a specific reason or event and returning it after use. Shoppers also practice bracketing, or purchasing an item in a variety of colors or sizes and then returning all the unwanted options.
Fourth, returns come with a steep cost in terms of sustainability, with returns amounting to 8.4 billion pounds of landfill waste in 2023 alone.
“As returns have become an integral part of the shopper experience, retailers must balance meeting sky-high expectations with rising costs, environmental impact, and fraudulent behaviors,” Amena Ali, CEO of Optoro, said in the firm’s “2024 Returns Unwrapped” report. “By understanding shoppers’ behaviors and preferences around returns, retailers can create returns experiences that embrace their needs while driving deeper loyalty and protecting their bottom line.”
Facing an evolving supply chain landscape in 2025, companies are being forced to rethink their distribution strategies to cope with challenges like rising cost pressures, persistent labor shortages, and the complexities of managing SKU proliferation.
1. Optimize labor productivity and costs. Forward-thinking businesses are leveraging technology to get more done with fewer resources through approaches like slotting optimization, automation and robotics, and inventory visibility.
2. Maximize capacity with smart solutions. With e-commerce volumes rising, facilities need to handle more SKUs and orders without expanding their physical footprint. That can be achieved through high-density storage and dynamic throughput.
3. Streamline returns management. Returns are a growing challenge, thanks to the continued growth of e-commerce and the consumer practice of bracketing. Businesses can handle that with smarter reverse logistics processes like automated returns processing and reverse logistics visibility.
4. Accelerate order fulfillment with robotics. Robotic solutions are transforming the way orders are fulfilled, helping businesses meet customer expectations faster and more accurately than ever before by using autonomous mobile robots (AMRs and robotic picking.
5. Enhance end-of-line packaging. The final step in the supply chain is often the most visible to customers. So optimizing packaging processes can reduce costs, improve efficiency, and support sustainability goals through automated packaging systems and sustainability initiatives.
Keith Moore is CEO of AutoScheduler.AI, a warehouse resource planning and optimization platform that integrates with a customer's warehouse management system to orchestrate and optimize all activities at the site. Prior to venturing into the supply chain business, Moore was a director of product management at software startup SparkCognition. He is a graduate of the University of Tennessee, where he earned a Bachelor of Science degree in mechanical engineering.
Q: Autoscheduler provides tools for warehouse orchestration—a term some readers may not be familiar with. Could you explain what warehouse orchestration means?
A: Warehouse orchestration tools are software control layers that synthesize data from existing systems to eliminate costly delays, streamline inefficient workflows, and [prevent the waste of] resources in distribution operations. These platforms empower warehouses to optimize operations, enhance productivity, and improve order accuracy by dynamically prioritizing work continuously to ensure that the operation is always running optimally. This leads to faster trailer turn times, reduced costs, and a network that runs like clockwork, even during fluctuating demands.
Q: How is orchestration different from a typical warehouse management system?
A: A warehouse management system (WMS) focuses on tracking inventory and managing warehouse operations. Warehouse orchestration goes a step further by integrating and optimizing all aspects of warehouse activities in a capacity-constrained way. Orchestration provides a dynamic, real-time layer that coordinates various systems and processes, enabling more agile and responsive operations. It enhances decision-making by considering multiple variables and constraints.
Q: How does warehouse orchestration help facilities make their workers more productive?
A: Two ways to make labor in a warehouse more productive are to work harder and to work smarter. For teams that want to work harder, most companies use a labor management system to track individual performances against an expected standard. Warehouse orchestration technology focuses on the other side of the coin, helping warehouses "work smarter."
Warehouse orchestration technology optimizes labor by providing real-time insights into workload demands and resource availability based on actual fluctuating constraints around the building. It enables dynamic task assignments based on current priorities and worker skills, ensuring that labor is allocated where it's needed most, even accounting for equipment availability, flow constraints, and overall work speed. This approach reduces idle time, balances workloads, and enhances employee productivity.
Q: How can visibility improve operations?
A: Due to the software ecosystem in place today, most distribution operations are highly reactive environments where there is always a "hair on fire" problem that needs to be solved. By leveraging orchestration technologies, this problem is mitigated because you're providing the site with added visibility into the past, present, and future state of the operation. This opens up a vast number of doors for distribution leadership. They go from learning about a problem after it's happened to gaining the ability to inform customers and transportation teams about potential service issues that are 24 hours away.