In our continuing series of discussions with top supply-chain company executives, Denis Reilly of Kenco discusses disruptions from Covid-19, digital transformation, and the quest for innovation.
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.
Denis Reilly is president and CEO of Kenco, a third-party logistics provider (3PL) whose services include distribution, transportation management, material handling equipment and fleet services, e-commerce fulfillment, and supply chain intelligence solutions.
Reilly has more than 35 years of experience in the logistics industry. Prior to joining Kenco in 2017, he was the CEO of St. George Logistics and has held executive and senior leadership posts with USA Dry Van Logistics, Geodis, MIQ Logistics, and Menlo Logistics. He began his career in logistics with Frito-Lay in 1983.
Reilly is a member of the Kenco board of directors, the Council of Supply Chain Management Professionals (CSCMP), and the University of Tennessee Global Supply Chain Institute Advisory Board. A graduate of the University of Tennessee, he holds a bachelor’s degree in logistics and an MBA in logistics and marketing. He recently spoke with DC Velocity Editorial Director David Maloney.
Q: How have Kenco’s operations been affected by the Covid-19 crisis?
A: Many, if not all, businesses across the nation have felt the impact of this pandemic, including 3PLs. At Kenco, we manage numerous supply chains across various industries. Encompassing over 90 distribution centers across North America, these supply chains range from ones that put food on peoples’ tables to those that ensure medical supplies are delivered to hospitals.
Our day-to-day operations have changed in accordance with the CDC [Centers for Disease Control and Prevention] guidelines and our efforts to protect the health of our employees. We initiated a Covid-19 Task Force months ago to focus on ensuring the safety of our employees while ensuring business continuity. Like many, we quickly converted our headquarters staff to work at home and, in the field, adopted the recommended social distancing policies, temperature checks, quarantines when applicable, enhanced cleaning processes, and adoption of face coverings.
Many of our customers have experienced significant and sudden volume changes. Some customers, such as those in the food, consumer packed goods (CPG), and health-care industries, have seen increases in demand of 30% to 200%, while others have experienced significant decreases. The challenges associated with significant demand spikes were managed through collaborative planning and the “can-do” attitude of our associates.
We are working with all customers to help them optimize and reduce costs during this challenging time. And our engineers and other supply chain professionals are prepared to help customers regain and recover when the coronavirus situation improves for their businesses and industries.
As the Covid-19 pandemic crisis evolves, we continue to monitor the situation and take appropriate actions to address potential concerns and risks. As always, Kenco’s primary focus is on the health and safety of our associates and customers.
Q: How will Covid-19 change future supply chain design?
A: The effect that Covid-19 has had on the supply chain is unlike any other disruption I’ve ever witnessed. A disruption of this size will absolutely impact many facets of the supply chain, including strategic design and tactical execution.
For example, we will likely see a resurgence of nearshoring or movement of some manufacturing back into the U.S., especially around key ingredients and products in the health-care industry. This pandemic will accelerate the growth of e-commerce, as during this time, everyone is getting accustomed to buying online.
In addition, the adoption of automation in distribution operations will probably accelerate, providing enhanced scalability and productivity. Finally, I think there will be a renewed focus on resilient supply chains and contingency planning. Strategies such as adding manufacturing and distribution locations, port diversification, and increased safety stocks will be essential to prevent future disruptions to supply chains.
Q: Kenco offers a wide array of supply chain services, from traditional warehousing and transportation to real estate management. How does that provide an advantage for your customers?
A: Kenco’s comprehensive solutions allow us to meet all of our customers’ needs across the supply chain. Customers typically outsource design and execution activities that are not their core competencies. We have the people, best practices, and technology that enable us to proactively look across our customers’ whole supply chain to drive efficiencies. In addition, our integrated solutions provide customers with a “one stop shop” for outsourcing, resulting in a competitive advantage from both a cost and service perspective.
Q: Innovation has been an emphasis for Kenco for many years, including the establishment of the Kenco Innovation Labs. How has this helped to serve the industry?
A: The world around us is continuously changing and so are the needs of the supply chain. The solutions that worked well in the past may not be adequate in the current and future environment. Therein lies the need for innovation.
Innovation is a key priority for Kenco because it allows us to provide our customers with best practices to meet their needs. In our Innovation Lab, we work with a wide variety of vendors to test emerging technologies in a real-world dedicated warehouse space. Our Innovation Lab functions as a formal space to review, research, and promote new ideas to bring futuristic solutions to our customers and the industry.
Vendors bring new technologies to our lab, where we can vet them carefully before implementing them in our day-to-day operations. We had one vendor bring in a robot for testing. It worked for a few days and then shut down. What we found was that there was a lot of pollen buildup around the sensors that caused it to shut down. The vendor made some quick modifications, and then its product worked effectively.
Another example is our development of the LoadProof app [a mobile app that photo-documents shipments as they move through the supply chain]. This was created through the collaboration of our warehouse operations and technology teams. The end result is a publicly available application that has become an industry standard in retail chargeback avoidance and compliance.
Q: Kenco is the largest woman-owned 3PL in the U.S. Does this unique status provide an advantage?
A: I view Kenco’s diversity as a competitive advantage because we choose the most talented individuals for every role, regardless of gender. At Kenco, we actively promote the advancement of women in an industry that is historically male-dominant.
From our chairwoman and owner to the vice president of innovation and the many women who are Kenco general managers operating fulfillment warehouses on behalf of our clients, women play a major role in our success. They are in these roles because they are the best at what they do. In recognition of this, a large CPG customer recognized Kenco for promoting the advancement of women by selecting us as its Woman-Owned Supplier of the Year.
Q: You have said that your vision for Kenco is that it will lead the digitalization of the supply chain. Why is that important?
A: I strongly support the digital transformation of the supply chain. At Kenco, digitalization is a top priority that we are taking very seriously, as is evidenced by our investment in technology, people, and our recent Innovation Lab expansion.
Most companies realize they need a digital transformation of their supply chain but lack the required knowledge, expertise, and focus to successfully achieve it. Kenco, as a supply chain solutions and services provider, sensed this market need early on and is working to lead the way in helping our customers with their transformation efforts.
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]."