Beauty products company Monat Global deftly managed explosive pandemic-driven growth thanks to a state-of-the-art DC that has maximized storage space and automated its picking process.
Victoria Kickham started her career as a newspaper reporter in the Boston area before moving into B2B journalism. She has covered manufacturing, distribution and supply chain issues for a variety of publications in the industrial and electronics sectors, and now writes about everything from forklift batteries to omnichannel business trends for DC Velocity.
Explosive e-commerce growth in 2020 sent many companies scrambling to meet increased order volumes, but not Florida-based Monat Global. The multinational distributor and direct seller of premium beauty products had already been hard at work developing a strategic plan to modernize its storage and fulfillment processes to meet growth projections, and was able to accelerate those plans to meet 2020’s burgeoning demand. The end result? A company that took a 200% increase in fulfillment volume in stride, and that is poised to meet double-digit growth projections through 2024.
“We were already growing at a good organic pace toward the end of 2019, and we knew at some point in time, we would run into space issues,” explains Matt Warner, Monat’s chief operating officer. “There was not enough space for all the storage of our product, and we knew that we’d cap out with our current shipping facility as well. And then our sales just took off [during the pandemic].
“[Thankfully,] we had already done a lot of the pre-work and were ready to meet the demand.”
Monat Global had teamed up with supply chain consulting company Alpine Supply Chain Solutions to get the ball rolling on expansion plans in 2019. The companies accelerated those plans in 2020, splitting the project into two phases—first addressing bulk storage and international shipping operations, and then installing automated solutions to streamline direct-to-consumer order picking and fulfillment. The plan involved moving to a new warehouse and distribution facility that would more than double the company’s existing space, and installing a set of material handling solutions that would allow for better space utilization and improved labor performance.
BULKING UP ON STORAGE
Monat had been outgrowing its 70,000-square-foot facility in suburban Miami, but the company would need more than just a larger facility to accommodate its projected growth. With Alpine’s help, company leaders found a 159,000-square-foot facility in Doral, Florida—close to its existing location—and immediately launched plans to maximize that footprint to allow for future growth. Monat’s existing facility featured single-deep pallet racking that was accessed by very narrow-aisle (VNA) forklifts; the new facility would feature high-density storage, incorporating drive-in-, select, and push-back racking to maximize space and improve overall productivity. This helped the company go from what would have been 5,000 pallet positions with its previous storage setup to more than 9,000 pallet positions in the new facility, according to Warner.
“We were really able to optimize that space,” he explains, emphasizing the benefits of the high-density storage system for the company’s long-term plans. “We had the space to grow; that was key. Next was space optimization and the flow [of products through the facility]. With our strategic master plan and storage-type analysis, that gave us great insight into how much of each type of storage and picking equipment we needed for all our activities.”
The phase one storage analysis and facility design/layout project streamlined the flow of pallets into and out of the facility, as well as cases of product going out, according to Michael Wohlwend, managing principal at Alpine Supply Chain Solutions.
Phase one was up and running by the summer of 2021.
STREAMLINING THE PICK PROCESS
Automation took hold in phase two, replacing Monat Global’s largely manual picking processes with a combination of solutions designed to increase speed and efficiency in the new warehouse and DC. Those solutions included conveyors and sorters, a pick-to-light system, and mobile computing and bar-code scanning as well as the implementation of SAP’s Extended Warehouse Management (EWM) system, which streamlines inventory management and goods movement through the warehouse. Those and other automated solutions helped minimize the labor required for picking and yielded a 48% improvement in lines filled per hour. Overall production through the facility per hour improved by 65%, according to Warner and Wohlwend.
“We also saw a major quality improvement to our customers with the new system,” Warner reports. “We have made a major leap forward. We’ve moved from a manual process to an automated system.”
The EWM system also helped with inbound receiving and pallet putaway—improving those processes by more than 300%. On the shipping side, automated packing and cartonization solutions helped streamline those functions, further reducing labor demands.
Phase two was up and running this past summer.
MAKING WAY FOR MORE AUTOMATION
Monat Global is now moving into phase three of its expansion plans, which includes beginning a discovery phase for opening another distribution hub in the Dallas area. Warner and Wohlwend say they will use the lessons learned in Florida to build a similar facility with maximized storage space and a slate of automated warehouse technologies. But they also plan to keep ramping up the automation in Florida, by continuously improving processes and adding new technologies where it makes sense. Future plans include implementing a learning management system for employee training and education, a labor management system, and an automated dock door scheduling system.
All told, the project is expected to deliver more than $3 million in cost savings.
“From my experience, having worked on a lot of big projects in my career … with the scope we have taken on, we’ve seen very good results,” says Warner. “We’ve taken steps that have changed our work in a big way.”
Wohlwend says it all comes back to strategic planning, adding that “world class preparation leads to flawless execution.”
Progress in generative AI (GenAI) is poised to impact business procurement processes through advancements in three areas—agentic reasoning, multimodality, and AI agents—according to Gartner Inc.
Those functions will redefine how procurement operates and significantly impact the agendas of chief procurement officers (CPOs). And 72% of procurement leaders are already prioritizing the integration of GenAI into their strategies, thus highlighting the recognition of its potential to drive significant improvements in efficiency and effectiveness, Gartner found in a survey conducted in July, 2024, with 258 global respondents.
Gartner defined the new functions as follows:
Agentic reasoning in GenAI allows for advanced decision-making processes that mimic human-like cognition. This capability will enable procurement functions to leverage GenAI to analyze complex scenarios and make informed decisions with greater accuracy and speed.
Multimodality refers to the ability of GenAI to process and integrate multiple forms of data, such as text, images, and audio. This will make GenAI more intuitively consumable to users and enhance procurement's ability to gather and analyze diverse information sources, leading to more comprehensive insights and better-informed strategies.
AI agents are autonomous systems that can perform tasks and make decisions on behalf of human operators. In procurement, these agents will automate procurement tasks and activities, freeing up human resources to focus on strategic initiatives, complex problem-solving and edge cases.
As CPOs look to maximize the value of GenAI in procurement, the study recommended three starting points: double down on data governance, develop and incorporate privacy standards into contracts, and increase procurement thresholds.
“These advancements will usher procurement into an era where the distance between ideas, insights, and actions will shorten rapidly,” Ryan Polk, senior director analyst in Gartner’s Supply Chain practice, said in a release. "Procurement leaders who build their foundation now through a focus on data quality, privacy and risk management have the potential to reap new levels of productivity and strategic value from the technology."
Businesses are cautiously optimistic as peak holiday shipping season draws near, with many anticipating year-over-year sales increases as they continue to battle challenging supply chain conditions.
That’s according to the DHL 2024 Peak Season Shipping Survey, released today by express shipping service provider DHL Express U.S. The company surveyed small and medium-sized enterprises (SMEs) to gauge their holiday business outlook compared to last year and found that a mix of optimism and “strategic caution” prevail ahead of this year’s peak.
Nearly half (48%) of the SMEs surveyed said they expect higher holiday sales compared to 2023, while 44% said they expect sales to remain on par with last year, and just 8% said they foresee a decline. Respondents said the main challenges to hitting those goals are supply chain problems (35%), inflation and fluctuating consumer demand (34%), staffing (16%), and inventory challenges (14%).
But respondents said they have strategies in place to tackle those issues. Many said they began preparing for holiday season earlier this year—with 45% saying they started planning in Q2 or earlier, up from 39% last year. Other strategies include expanding into international markets (35%) and leveraging holiday discounts (32%).
Sixty percent of respondents said they will prioritize personalized customer service as a way to enhance customer interactions and loyalty this year. Still others said they will invest in enhanced web and mobile experiences (23%) and eco-friendly practices (13%) to draw customers this holiday season.
That challenge is one of the reasons that fewer shoppers overall are satisfied with their shopping experiences lately, Lincolnshire, Illinois-based Zebra said in its “17th Annual Global Shopper Study.”th Annual Global Shopper Study.” While 85% of shoppers last year were satisfied with both the in-store and online experiences, only 81% in 2024 are satisfied with the in-store experience and just 79% with online shopping.
In response, most retailers (78%) say they are investing in technology tools that can help both frontline workers and those watching operations from behind the scenes to minimize theft and loss, Zebra said.
Just 38% of retailers currently use AI-based prescriptive analytics for loss prevention, but a much larger 50% say they plan to use it in the next 1-3 years. That was followed by self-checkout cameras and sensors (45%), computer vision (46%), and RFID tags and readers (42%) that are planned for use within the next three years, specifically for loss prevention.
Those strategies could help improve the brick and mortar shopping experience, since 78% of shoppers say it’s annoying when products are locked up or secured within cases. Adding to that frustration is that it’s hard to find an associate while shopping in stores these days, according to 70% of consumers. In response, some just walk out; one in five shoppers has left a store without getting what they needed because a retail associate wasn’t available to help, an increase over the past two years.
The survey also identified additional frustrations faced by retailers and associates:
challenges with offering easy options for click-and-collect or returns, despite high shopper demand for them
the struggle to confirm current inventory and pricing
lingering labor shortages and increasing loss incidents, even as shoppers return to stores
“Many retailers are laying the groundwork to build a modern store experience,” Matt Guiste, Global Retail Technology Strategist, Zebra Technologies, said in a release. “They are investing in mobile and intelligent automation technologies to help inform operational decisions and enable associates to do the things that keep shoppers happy.”
The survey was administered online by Azure Knowledge Corporation and included 4,200 adult shoppers (age 18+), decision-makers, and associates, who replied to questions about the topics of shopper experience, device and technology usage, and delivery and fulfillment in store and online.
An eight-year veteran of the Georgia company, Hakala will begin his new role on January 1, when the current CEO, Tero Peltomäki, will retire after a long and noteworthy career, continuing as a member of the board of directors, Cimcorp said.
According to Hakala, automation is an inevitable course in Cimcorp’s core sectors, and the company’s end-to-end capabilities will be crucial for clients’ success. In the past, both the tire and grocery retail industries have automated individual machines and parts of their operations. In recent years, automation has spread throughout the facilities, as companies want to be able to see their entire operation with one look, utilize analytics, optimize processes, and lead with data.
“Cimcorp has always grown by starting small in the new business segments. We’ve created one solution first, and as we’ve gained more knowledge of our clients’ challenges, we have been able to expand,” Hakala said in a release. “In every phase, we aim to bring our experience to the table and even challenge the client’s initial perspective. We are interested in what our client does and how it could be done better and more efficiently.”
Although many shoppers will
return to physical stores this holiday season, online shopping remains a driving force behind peak-season shipping challenges, especially when it comes to the last mile. Consumers still want fast, free shipping if they can get it—without any delays or disruptions to their holiday deliveries.
One disruptor that gets a lot of headlines this time of year is package theft—committed by so-called “porch pirates.” These are thieves who snatch parcels from front stairs, side porches, and driveways in neighborhoods across the country. The problem adds up to billions of dollars in stolen merchandise each year—not to mention headaches for shippers, parcel delivery companies, and, of course, consumers.
Given the scope of the problem, it’s no wonder online shoppers are worried about it—especially during holiday season. In its annual report on package theft trends, released in October, the
security-focused research and product review firm Security.org found that:
17% of Americans had a package stolen in the past three months, with the typical stolen parcel worth about $50. Some 44% said they’d had a package taken at some point in their life.
Package thieves poached more than $8 billion in merchandise over the past year.
18% of adults said they’d had a package stolen that contained a gift for someone else.
Ahead of the holiday season, 88% of adults said they were worried about theft of online purchases, with more than a quarter saying they were “extremely” or “very” concerned.
But it doesn’t have to be that way. There are some low-tech steps consumers can take to help guard against porch piracy along with some high-tech logistics-focused innovations in the pipeline that can protect deliveries in the last mile. First, some common-sense advice on avoiding package theft from the Security.org research:
Install a doorbell camera, which is a relatively low-cost deterrent.
Bring packages inside promptly or arrange to have them delivered to a secure location if no one will be at home.
Consider using click-and-collect options when possible.
If the retailer allows you to specify delivery-time windows, consider doing so to avoid having packages sit outside for extended periods.
These steps may sound basic, but they are by no means a given: Fewer than half of Americans consider the timing of deliveries, less than a third have a doorbell camera, and nearly one-fifth take no precautions to prevent package theft, according to the research.
Tech vendors are stepping up to help. One example is
Arrive AI, which develops smart mailboxes for last-mile delivery and pickup. The company says its Mailbox-as-a-Service (MaaS) platform will revolutionize the last mile by building a network of parcel-storage boxes that can be accessed by people, drones, or robots. In a nutshell: Packages are placed into a weatherproof box via drone, robot, driverless carrier, or traditional delivery method—and no one other than the rightful owner can access it.
Although the platform is still in development, the company already offers solutions for business clients looking to secure high-value deliveries and sensitive shipments. The health-care industry is one example: Arrive AI offers secure drone delivery of medical supplies, prescriptions, lab samples, and the like to hospitals and other health-care facilities. The platform provides real-time tracking, chain-of-custody controls, and theft-prevention features. Arrive is conducting short-term deployments between logistics companies and health-care partners now, according to a company spokesperson.
The MaaS solution has a pretty high cool factor. And the common-sense best practices just seem like solid advice. Maybe combining both is the key to a more secure last mile—during peak shipping season and throughout the year as well.