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.
If there’s one thing 2020 taught us, it’s the dangers of prognostication. Last year at this time, preparing a solid market forecast seemed like a slam-dunk: The economy was humming along, unemployment stood at record lows, and all indications were we could expect more of the same. Then, Covid-19 hit the U.S. economy like a wrecking ball, shuttering businesses, sending unemployment to new heights, and generally making hash of those expectations.
So what does all this mean for 2021? Is there any way to tell? Will the economy stabilize? Will the employment picture improve? And what does the turmoil of the past year portend for the logistics supply chain sector?
We didn’t have to look far to find someone who could weigh in on those questions—particularly those that relate to the supply chain. Our own Gary Master, publisher of DC Velocity and COO of Agile Business Media, has an extensive background in business economics along with 30-plus years’ experience in supply chain logistics. As an executive at a media company focused on the supply chain, he keeps close tabs on the market in general and the supply chain logistics market in particular. On top of that, he tracks general economic and supply chain trends along with developments in the retail and manufacturing sectors—which, taken together, he says, give you a good picture of what’s going on.
As 2020 drew to a close, Editorial Director David Maloney sat down with Gary to get his take on what lies ahead—where the markets are heading, the trends taking shape in warehouse design, and how the pandemic will reshape supply chain operations.
Q: Obviously, 2020 was a roller coaster year for nearly every facet of the supply chain. As we begin 2021, what are your overall impressions looking forward?
A: I think it helps to take a quick look back at 2020 in order to understand where we are with 2021. 2020 brought the strongest economic shocks you could possibly have. In the second quarter, we had the single greatest percentage drop in GDP (gross domestic product) year over year, quarter over quarter, ever. And then in the third quarter, we had the greatest rise in GDP ever. So, it was just a remarkable year from an economic standpoint, when you look at that wide variance.
Now, as we enter 2021 with the shock and awe behind us, we are trying to figure out where we go from here. I think that when you look at 2021, you’ve got acceleration of certain industries, you have the new administration in Washington, and you have the vaccines that give us all hope. Vaccinations are going to help boost economic growth and activity in 2021.
Q: Where do you see the material handling market heading this year?
A: I think you are going to see a steady continuation of activity. Despite the conditions in 2020, we had hot areas, such as food and grocery delivery. We had micro fulfillment making inroads. We had the e-commerce boom and escalating demand for last-mile delivery service. All those things are going to continue to be hot in 2021. Covid has just accelerated the growth of those areas.
Q: There’s also a lot of pent-up demand with projects that were put on hold in 2020. Companies have the cash but have been afraid to spend it during the pandemic. Do you foresee a loosening of those purse strings?
A: That is a great question. The answer is yes and no. Will vaccinations and rising business confidence help shake some of those projects loose? The answer is yes. We have already seen several major projects—some involving the construction of massive distribution centers—getting approved and going forward. That’s the positive side.
On the negative side, you’ve got some companies that, with Covid-related expenses, with economic uncertainty, and with a downturn in business, are now a bit cash-strapped. So, they are caught between the need to make changes and a lack of cash to make those changes.
Even so, I think you are going to see some companies really step it up and launch major projects. Others are going to be more cautious because of their cash position. Overall, the economic fundamentals are good—with the exception of unemployment, which is way too high.
Q: Do you think that once we get through the current wave of Covid cases, the unemployment rate will drop, especially as vaccinations become more widely available?
A: Yes, that is the assumption most people are making right now. Despite the surge in cases this winter, the vaccines’ arrival gives us hope that we can get the pandemic under control and return to a normal way of life. Could you imagine that? A normal way of life, Dave? Sitting on an airplane without a mask. Going to an actual—not virtual—event? Wouldn’t that be a wonderful world?
Q: It certainly would be. So much of economics is based on trust and confidence. What has to happen in 2021 to rebuild consumer confidence and nudge us back toward normalcy?
A: I think there are a couple of things. The number-one critical component is getting more vaccines approved and more people vaccinated. I think once we see immunization rates begin to rise and hear that it’s starting to take hold, that gives us hope. And then you start thinking about being able to travel again and going on vacation. You start thinking about being able to go to gatherings and events. That builds confidence and trust. From an economic standpoint, that is a really, really good thing. So, I think getting people vaccinated is number one.
I think number two is what happens in Washington. A government held in check by both parties is good for the economy, as it keeps that government on a more centrist course. Economically, it’s good for businesses when there’s little risk of the government making a radical right or left turn. They are able to plan based on normal growth trends and economic conditions. I think those are two things that are particularly critical right now in gaining the trust of the consumer and the business community.
Q: You mentioned the high unemployment rate. How will this affect our supply chains going forward?
A: Before 2020, all we talked about was labor shortages, labor shortages, labor shortages. Now, we’re in a situation where upwards of 20 million people are unemployed. It might seem that we could solve all of our problems by simply taking those unemployed individuals and putting them to work in the material handling sector. But it is not as easy as it sounds.
The other thing is, it is a risk. Human workers get sick and can’t be counted on during a pandemic, when they could be quarantined or sidelined by illness for some time. So, even though we have a high unemployment rate, we still have a business environment that is risk-averse. That means there is now an even greater need for automation to take that labor risk out of your business.
I think you are going to continue to see robotics grow. We keep hearing how companies are looking to employ robots in any way they can throughout their operations—from manufacturing to warehousing and distribution, where they perform picking, packing, put-away, and truck-loading tasks. Everybody is looking at anything that can be done with robotics.
The pandemic has also underscored the need for flexibility. We don’t know what is going to happen in the future or even tomorrow. Everybody is looking to add flexibility to their operations. Robotics and automated solutions create flexibility.
Q: Labor concerns could also have repercussions for facility design. After the Great Recession, we saw companies make design changes aimed at reducing their reliance on labor, as they were cautious about increasing headcount even when conditions improved. I think we can expect this pandemic to have a similar effect on the way companies design facilities.
A: That is a great point, Dave. It is the pendulum effect, right? I think right now, a lot of folks are looking at labor usage within their facilities and how they can reduce their staffing needs. It is a cost issue, but it’s also about efficiency, accuracy, and reducing their exposure to risk.
Q: Transportation also had a long, strange ride in 2020, with business nearly falling off a cliff in the middle of the year before rebounding in the fall to record-breaking levels. What do you see ahead for transportation as we begin 2021?
A: I think you hit the nail on the head. When you look at utilization, rates, and everything else across the board in transportation, it’s been a very weird year. With all the consolidation we’ve had within transportation, we lost a lot of capacity, which left the market susceptible to shortages.
I am hoping that when the new administration starts to look at economic stimulus and spending, it will consider the needs of our nation’s infrastructure. I think that if we move forward with infrastructure projects and make needed repairs quickly, it will make the transportation sector more efficient.
I am also really concerned about shipping rates, especially the “Amazon effect” and consumers’ expectation of free shipping. That’s been going on for some time now, but it just puts pressure on what companies can charge for shipping and threatens their profitability. We just really need innovation on the transportation side.
Then, lastly, there’s the matter of helping individuals understand that transportation could be a great career opportunity. I mean that from the truck driver on up. Getting more trucks on the road, getting more individuals to see driving as a viable career path—I think both of those are critical to bolstering the transportation segment.
Q: Are there things we can do to make our supply chains more efficient?
A: I think the pandemic has demonstrated the risks of global sourcing and the need to find sources closer to home. We easily fall into the old trap of cost, while risk avoidance falls down the ladder. I hope that we as a global society have learned our lesson and that we are really thinking about creating a truly resilient supply chain.
Overall, I think we can feel good about 2021 with the vaccinations coming. We will see a 3.0% to 3.5% increase in business overall next year and maybe 2.8% to 3.5% year-over-year growth in GDP. I also think that we will see across-the-board growth in the material handling industry, with certain segments—like robotics, automation, software, and services—doing particularly well. I think you are going to see a good strong year in those areas, so I am excited about 2021. Quite frankly, I am glad to see 2020 leave.
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]."