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ForwardX Robotics has joined hands with the world’s largest cosmetics company to open a new era of person-to-goods smart warehouses.
The world’s largest cosmetics company faced many business challenges at its Suzhou warehouse in China before it upgraded its operations.
In a time when consumers’ expectations of quick and accurate deliveries are rising, technology is undoubtedly one of the most effective means at meeting their demands.
In recent years, due to COVID-19 and other variables, eCommerce has grown faster than ever and put extra strain on peak seasons and shopping holidays such as Black Friday and Cyber Monday. Fast deliveries, sometimes as quick as next-day or even same-day, are becoming the norm for consumers. Companies that can’t deliver at this rate risk losing market share to their competition that can. If a business wants to stay competitive in today’s climate, continuous improvements in its warehousing and logistics workflows need to be implemented.
The world’s largest cosmetics company, with more than 20 brands and sales channels all over the world, has always maintained a leading position in the beauty and cosmetics industry. Its Suzhou warehouse in China was facing many business challenges before it upgraded its operations.
Pain Points
1. Low picking efficiency
The previous workflows of this warehouse were traditional manual picking and sorting. Personnel needed to walk the length of the warehouse to fulfill orders while hauling carts that weighed between 1,100–1,322 lbs. This design was labor-intensive and physically exhausting for employees. Naturally, movement speed was slow and consisted of many “empty walks” resulting in a low picking efficiency that couldn’t support the volume of orders and shipments this warehouse needed to meet.
2. High labor intensity
The laborious nature of the manual picking not only resulted in inefficient order fulfillment, but it also caused a high rate of employee turnover. This makes for labor costs and recruitment costs that are too high to be sustainable for the business.
3. Complicated picking processes
The warehouse mainly deals in B2B fulfillment. Different from the B2C practices which result in generally small orders that many automation solutions can be applied, this warehouse was dealing with large pallets and case-picking to fulfill orders. Most flexible solutions available couldn’t support these kinds of workflows. In addition, the warehouse ships out a daily average of over 25,000 boxes.
In order to solve these business pain points, the beauty group decided to collaborate with Asia’s No. 1 person-to-goods solution provider, ForwardX Robotics.
Results
ForwardX successfully deployed over 10 AMRs in the group’s Suzhou warehouse to realize an intelligent person-to-goods picking solution. The picking area is about 53,800 square feet. After 1 month of on-site POC operations, the flexibility and efficiency were obvious. Processing over 20,000 orders per day, the UPH has increased by more than 40%, delivery accuracy reached 99.99%, and 100% of orders went out on time.
How These Results Were Achieved
Picking processes are at the base of warehousing and logistics, and the efficiency at which the process runs directly effects operating costs and the overall workflows through the entire logistics of any distribution center.
By introducing ForwardX’s AMRs and f(x) Fleet Manager, optimizing the cluster scheduling system, this cosmetics giant transformed its original traditional manual methods into a flexible automated person-to-goods solution through AMR collaboration.
When an order is received, an AMR automatically takes an empty pallet to the picking zones to work with employees on the floor fulfilling the order. After the picking is complete for that order, the AMR brings the full pallet to the shipping area while the employees remain in their zones fulfilling other orders with other AMRs continuously going through the process.
The f(x) Fleet Manager optimizes routes through an AI algorithm and directs the workflows. Picking rates drastically improve by having each person work with multiple AMRs and each AMR work with multiple people. An employee’s time is no longer spent on traversing the warehouse, and instead is spent cooperating with AMRs that meet them in their respective picking zones.
The AMRs are also incredibly flexible and scalable to cope with order surges brought on by shopping holidays or product promotions. The size of an order in regards to weight, doesn’t slow down operations when an AMR is the one hauling an order through the warehouse.
Through human-machine collaboration, production has increased by more than 40%, and the labor intensity has been significantly reduced resulting in about 43% savings in labor costs and a large reduction in personnel turnover.
Safety
AMRs must work in the same environment with people, carts, pallets, and manual forklifts while hauling thousands of pounds. In most warehouses, several operation methods exist simultaneously, and paths are often crossed. Safety is of the upmost importance when considering an automation solution.
ForwardX AMRs use a variety of sensors and cameras to realize 360° obstacle detection and avoidance while also being able to perceive the environment and identify moving and static objects or people. The AMR control system can instruct the AMRs to use different obstacle avoidance strategies based on the type of obstacles encountered.
The internal safety department of the cosmetics company conducted several comprehensive safety tests on the software and hardware behind the solution. In addition, a professional third-party safety certification body came onsite to test the AMRs. ForwardX’s AMRs successfully passed the various internal and third-party tests to ensure safe operations where humans and machines work together.
Fast Deployment and Cost Savings
ForwardX’s flexible person-to-goods picking solution adapts to its environment, instead of the other way around. For most automation solutions, a warehouse needs to rearrange, rebuild, or even build a new warehouse around the automation design. With ForwardX AMRs, no remodeling is required. This makes for rapid deployment with zero downtime in operations and zero hidden costs to consumers. Opting for the Robots as a Service (RaaS) model has an ROI of just 5–9 months.
In addition, ForwardX’s solution is scalable to meet demand spikes in peak seasons or during product promotions. The warehouse can increase or decrease the number of AMRs quickly to match the daily order volume at any given time.
Precision and Accuracy
ForwardX’s software and hardware seamlessly connect with existing APR/WMS/MES systems in the warehouse. f(x) Fleet Manager’s cluster scheduling organizes orders according to multiple different strategies and intelligently assigns tasks to the AMR fleet with the capability of commanding up to 200 AMRs at once.
Prompts are given to pickers via handhelds and/or on the AMR screen to guide workflows and simplify the process for employees. A picker selects the nearest AMR to receive a task and complete each pick. At the same time, they print and paste the label and confirm each pick on the spot, leading to much higher accuracy.
f(x) Fleet Manager also generates digital reports based on KPIs that the customer is most interested in. With a user-friendly UI, decision makers can monitor every aspect of the process from the progress of an on-site order, UPH per picker, top performing personnel, to an electronic map of the floor and real-time AMR location information. These digital displays provide reliable, actionable information for further improvement of production efficiency.
Post-Project
Based on the results of the pilot project with ForwardX and the well-known cosmetics company, both sides are getting ready to start follow-up projects and significantly scale up the current project.
The cooperation with the world’s largest cosmetics company has given ForwardX even more credibility and proof of the results that can be achieved. This scenario is not limited to the beauty industry as it can be easily replicated in other industries using similar storage and picking workflows on beam shelves.
Conclusion
Whether due to COVID-19 or other factors, the warehousing industry is facing a variety of substantial challenges in today’s market. From inventory records and labor costs to employee retention rate, customer experience, and more, it’s imperative for companies to find solutions in order to stay relevant. Market demand has accelerated technological innovation, and AMRs are the latest, most flexible solution available, addressing multiple pain points at once.
ForwardX’s flexible person-to-goods solution has been the light at the end of the tunnel for many of the world’s leading companies such as TCL; JD.com; DHL partner, SF Supply Chain China; Toyoda Gosei; and more. Asia’s No. 1 person-to-goods solution provider will continue innovating and helping customers gain a new momentum in the market while providing better performance and a better value.
About ForwardX Robotics
ForwardX Robotics is a global technology leader in the fields of AI and Robotics. Through its flexible automation platform comprising of intelligent mobile robots and AI-enabled software, ForwardX delivers material handling solutions for warehousing and manufacturing facilities that offer better performance at better value. The company is comprised of over 250 members hailing from top universities and leading enterprises around the world. As shown by its 100+ patents granted, along with its award-winning research work, such as 2 1st-Place Prizes at TRECVID and the 1st-Place Prize at IEEE’s VOT-RT, ForwardX’s team boasts some of the world’s top computer vision scientists and robotics experts.
With offices in China, Japan, and the US, along with partnerships around the globe, ForwardX is expanding and applying its proven solutions to warehouses and manufacturers worldwide. For more information, visit www.forwardx.com.
Nulogy, a leading provider in supply chain collaboration solutions, and Kinaxis, a global leader in supply chain orchestration, have announced a partnership to develop cutting-edge solutions for brand manufacturing supply chain networks worldwide.
The new partnership aims to catalyze fast-moving consumer goods (FMCG) and life science brands and their supplier networks to work together more effectively through digital transformation solutions, thereby mutually improving costs, service and revenue. Combining the supply chain orchestration capabilities of Kinaxis with the collaborative external manufacturing specialization of Nulogy will enable customers to share forecasts and order information with suppliers and receive inventory capacity information faster.
Nulogy’s purpose-built multi-enterprise platform enables greater responsiveness in the supply networks of leading FMCG and life science brands, including L’Oréal, Colgate-Palmolive, and Church & Dwight, as well as their extended suppliers and hundreds of sites around the world.
“Given the speed and volatility of today’s global market, it is more important than ever for brand manufacturers to digitally synchronize with their supplier communities in order to respond with agility,” said Jason Tham, CEO at Nulogy. “Through our partnership with Kinaxis, we look forward to collaborations that will elevate the performance of supply chain networks around the world.”
Kinaxis Maestro is the AI-infused end-to-end supply chain orchestration platform for fast, intelligent decision-making. Trusted by renowned global brands to provide agility and predictability to help navigate volatility and disruptions, Kinaxis has been a leader in supply chain planning for over 40 years.
"Our partnership with Nulogy improves visibility, control and collaboration of the upstream network of critical suppliers, like contract manufacturers and co-packers, by integrating a variety of supplier data into Maestro,” said Bill Walker, Senior Director, Partner Solutions Extensions at Kinaxis. “Giving our customers the ability to better run simulations, digitize planning and connect in suppliers.”
Learn more about the partnership at ASCM Connect on September 9, 2024. Kevin Wong, Chief Operating Officer, Nulogy; Polly Mitchell-Guthrie, Supply Chain Thought Leader, Kinaxis; and German Vizcaya Leon, VP Global Planning, Colgate-Palmolive will discuss how Nulogy and Kinaxis’s solutions in Advanced Planning & Scheduling and Supplier Collaboration have played pivotal roles in interconnecting Colgate’s network.
FOR IMMEDIATE RELEASE
Contact: Sherri Bosslet
Title: Director of Customer Relations
Phone: 937.415.1715
Email: sbosslet@daytonfreight.com
Date: September 5, 2024
Web: daytonfreight.com
ULINE AWARDED DAYTON FREIGHT FOR EXCEPTIONAL PERFORMANCE
DAYTON, Ohio – Dayton Freight Lines, Inc., a leading provider of regional less-than-truckload (LTL) transportation services, was presented the 2023 Exceptional Performance Award and the Minnesota LTL Carrier of the Year award from Uline.
The 2023 Exceptional Performance Award and the Minnesota LTL Carrier of the Year award were presented to Dayton Freight’s Milwaukee and Hudson Service Centers, respectively. Both awards were given based on the following criteria: exemplary customer service, technological innovation and lastly, partnership and dedication.
Uline, a family-owned business, is the leading distributor of shipping, industrial and packaging materials to businesses throughout North America.
Dayton Freight’s Director of Customer Relations, Sherri Bosslet quoted, “We are incredibly proud of our Service Centers in Milwaukee and Hudson WI for receiving these awards. These accolades from Uline truly demonstrate the dedication and diligence of our Dayton Freight team. We look forward to a lasting partnership for years to come.”
Founded in 1981, Dayton Freight is a private, union-free, less-than truckload (LTL) freight carrier headquartered in Dayton, Ohio. Currently ranked as the country’s 12th largest LTL company, Dayton Freight has 70 Service Centers in 14 Midwest states, served by 6,000+ employees. Offering 1 or 2 day service to thousands of cities, Dayton Freight is known for its prudent growth, operational excellence, advanced technology and an unparalleled company culture known as The Dayton Difference.
Photo Caption: Jeremy Cutchens (Dayton Freight), Shelly Hofmeister (Dayton Freight), Ed VanGrouw (Dayton Freight), Eric Dreissig (Uline), LJ Groen (Uline)
Nulogy, a leading provider of supply chain collaboration solutions, is hosting a session during the Association of Supply Chain Management's ASCM Connect 2024. Nulogy, Kinaxis and Colgate-Palmolive executives will present “Orchestrating Digital Transformation: Nulogy & Kinaxis Empower Colgate-Palmolive’s External Network” on Monday, 9/9/2024, 3:45 - 4:45 p.m. CT in Ballroom E, Level 4.
In an era when digital transformation is paramount for sustainable growth, Colgate-Palmolive stands out as a leader in the consumer packaged goods space. With a strong digital transformation vision and strategic partners that tout the technical capabilities and expertise to bring it to life, Colgate and its extended supply network has been able to reap the benefits of digitally-infused agility, resilience and efficiency to outcompete in today’s marketplace.
The session will cover Colgate-Palmolive’s vision for transforming its supply chain planning and execution, highlighting the imperative to enhance supply chain synchronization and collaboration.
Nulogy and Kinaxis join Colgate-Palmolive in this talk to discuss how their best-of-breed solutions in advanced planning and scheduling and supplier collaboration have played pivotal roles in interconnecting Colgate’s network.
Speakers include:
Moderator: Christine Barnhart, CPIM Chief Marketing and Industry Officer, Nuology
Panelist: Kevin Wong Chief Operating Officer, Nulogy
Panelist: Polly Mitchell-Guthrie Supply Chain Thought Leader, Kinaxis
Panelist: German Vizcaya Leon VP Global Planning, Colgate-Palmolive
Check out the complete Colgate-Palmolive case study by visiting https://bit.ly/3z6xwPK.
Covington, KY — In a significant step toward redefining supply chain efficiency and boosting the local economy, Lakeshore Learning hired Zion Solutions Group, a trailblazer in advanced supply chain integration, to help implement a cutting-edge 1.2 million square foot distribution center in Garland, Utah. This collaboration is set to create over 500 jobs, showcasing an unparalleled commitment to innovation and community development.
“Our relationship with Lakeshore Learning, beginning in 2015, has been a testament to what visionary collaboration can achieve," stated Jim Shaw, President of Zion Solutions Group. “This is not just a collaboration; it’s a leap toward the future of supply chain management. By combining Lakeshore Learning’s vision with our technological expertise, we are set to introduce a distribution hub that exemplifies efficiency, sustainability, and economic growth for Garland."
Artin Ghazarian, Chief Supply Chain Officer at Lakeshore Learning, highlighted the project's ambition: "Our journey with Zion Solutions Group has been marked by a shared drive for excellence. This distribution center goes beyond expanding our logistical capabilities—it's a testament to our dedication to setting new industry standards for efficiency and environmental stewardship in supply chain management."
Jordan Frank, EVP & Co-Founder of Zion Solutions Group, emphasized the collaborative synergy: Our relationship with Lakeshore Learning is more than a partnership; it's a melding of minds aimed at redefining the future of our industry. We're not just optimizing logistics; we're crafting a model of innovation that leverages technology for smarter, more sustainable operations. Our goal is to inspire the sector by demonstrating how collaboration and technology together can create impactful solutions.”
The facility will harness the latest in automation and robotics to optimize both efficiency and scalability. Zion Solutions Group will play a crucial role in this evolution, meticulously shaping the project from its conceptual stages to its final form. This includes value-added engineering to support Lakeshore Learning’s specific needs, overseeing the procurement and engineering processes to ensure precision, and integrating advanced software solutions—including Zion Apex (WES)—for peak functionality. Beyond the project’s completion, Zion’s Customer Experience team will continue to support the operations team and provide optimization opportunities, ensuring the facility operates smoothly and evolves with technological advancements.
With an operational goal set for 2025, Lakeshore Learning’s Garland distribution center represents a major milestone in job creation and economic growth for the region. This initiative aligns with Zion's mission to drive sustainable innovation and cement its leadership in the market.
For more information about Zion Solutions Group and its groundbreaking projects, please visit https://thezsg.com/.
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About Zion Solutions Group
Zion Solutions Group, a leader in Supply Chain Integration, uses its 90+ years of knowledge to deliver memorable experiences and guide intelligent change. Specializing in material handling integration, Zion provides comprehensive services that include detailed data analytics, solution design, procurement, implementation, and post-implementation support. Our customer-centric approach and Project Lifecycle process ensure tailor-made solutions using cutting-edge technology, setting us apart in the industry. Zion, in support of its core purpose, “To Leave a Positive Impact on the Lives of Those We Touch,” is committed to driving success and sustainable growth for our partners and customers.
About Lakeshore—Products Designed with Learning in Mind®
Lakeshore Learning Materials is a leading developer and retailer of top-quality materials for early childhood education programs, elementary schools, and homes nationwide. Since 1954, Lakeshore Learning Materials has offered innovative learning materials distinguished by their quality, educational merit, and safety. To learn more, visit LakeshoreLearning.com.
Panel Built, Inc., a leading provider of modular offices, mezzanines, and custom-engineered structures, has announced plans to expand its primary facility, PB1. The expansion will include additional office and fabrication space, allowing the company to better accommodate its rapidly growing workforce and increasing demand for its innovative space solutions.
As Panel Built continues to experience significant growth in both personnel and market reach, this expansion marks a critical step in the company’s strategic development. The additional space will enable the company to enhance its operational efficiency and continue delivering high-quality products and services to its diverse client base. The expanded facility will also provide a more collaborative work environment for the Panel Built team, fostering innovation and reinforcing the company’s commitment to excellence.
"Panel Built has built a reputation for delivering modular solutions that meet the unique requirements of various industries, including commercial, military, government, and industrial sectors. The company's expertise in engineering, design, and installation has made it a trusted partner for organizations seeking efficient and customizable space solutions.
The Blairsville facility expansion is expected to be completed by early 2025. Panel Built is committed to maintaining uninterrupted service to its clients throughout the construction process, ensuring that all projects remain on schedule and meet the company’s high standards of quality."
- Mike Kiernan CEO
About Panel Built, Inc.
Founded with the mission "To Solve Our Customers' Space Needs With Excellence And Great Customer Service," Panel Built, Inc. specializes in modular construction, offering a range of solutions from modular offices and mezzanines to guardhouses and cleanrooms. With extensive experience in both public and private sectors, Panel Built is dedicated to delivering space solutions that meet the highest standards of quality, safety, and customer satisfaction.