Online retailer Ecentria set out to reconfigure its distribution network and install automated warehouse systems to meet growth demands—and in the process, uncovered opportunities for small changes that have yielded big results ahead of the planned high-tech implementations.
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.
Developing a warehouse automation project takes time and strategic planning, and it often involves consulting experts who can analyze your operations, growth expectations, and long-term objectives in order to determine the best course of action. That’s exactly what leaders at outdoor equipment and tactical gear retailer Ecentria set out to do in 2022 after experiencing 200% growth in a single year and realizing they didn’t have the right systems in place to handle that kind of demand. Company leaders say they needed a plan to handle growth while also reducing costs, increasing productivity, and cutting fulfillment and delivery times for their global customer base, which includes hunters and outdoor enthusiasts as well as the military and first responders. The company sells direct to consumers as well as to business and government accounts.
“We needed a better system for managing inventory and fulfilling orders, and one that would [accommodate] future growth,” explains Chris Batt, Ecentria’s director of fulfillment and distribution center operations, adding that the company’s two-facility network included some robotic picking systems that weren’t meeting its complex inventory requirements. Ecentria is an online-only business that handles about 130,000 stock-keeping units (SKUs) across its two distribution centers (DCs). Those items vary widely in size and type, ranging from an expandable camper that fits on top of a car all the way down to small hardware items, such as specialty screws.
As Batt explains, Ecentria needed a partner that could objectively analyze its processes and recommend automated systems and DC network design changes that would help it speed fulfillment and delivery while trimming costs. The company turned to material handling systems integrator Alpine Supply Chain Solutions and within five months, was making small changes that were yielding big results, with an ultimate plan to reconfigure Ecentria’s DC network and implement large-scale automation.
“Analysis is what has made the difference here,” Batt says, explaining that a deep dive into inventory movement, demand fluctuation, and projected growth helped identify DC layout changes and slotting adjustments that have led to better productivity and labor savings before the broader automation and network redesign project has even begun.
“We’re getting more benefits than we thought possible,” Batt says.
IMMEDIATE GAINS
Ecentria’s company headquarters and primary DC are located in Aurora, Illinois, near Chicago, and its second facility is in Logan, Utah, about 85 miles north of Salt Lake City. Both facilities handle the full range of the company’s SKUs, with the exception of ammunition, which Ecentria supplies only out of the Utah site. Alpine’s first step was to conduct a storage-type analysis and automation evaluation for both facilities to determine how the company could make better use of existing space both now and in the future, given the wide variety of items stored and shipped. After analyzing A, B, and C items based on their pick location and reserve stocking location in the facilities, and factoring in projected volume growth of 20% year over year from 2022 through 2026, Alpine recommended “rightsizing” the space in each facility to improve putaway, storage, and fulfillment—advice Ecentria acted on immediately. Managers reconfigured much of the space and then reslotted items—the process of determining where products are best positioned in a warehouse or DC—for better, more efficient movement through both facilities.
As part of the analysis, Alpine and Ecentria collaborated to build a 3D computer model of the facilities, which Batt and his colleagues say helped them better understand existing processes and visualize recommended changes. Those changes included replacing wide-aisle racking with very-narrow-aisle (VNA) racking systems—a modified form of adjustable pallet racking that increases storage density—in parts of both facilities. In Aurora, the plan called for putting 3,000 high-velocity A and B SKUs —the fastest-moving items in the facility—in a central location for more concentrated picking. Workers used radio-frequency (RF) scanning devices for picking prior to the change and continue to do so in the new layout.
The initial changes have produced big results, including a more than 60% improvement in the company’s average pick rate. As of this past spring, Ecentria’s employees had gone from an average of 56 picks per hour to 91 picks per hour during peak periods. The new system has also reduced employees’ travel time throughout the facility, optimized forklift usage (no more empty or idle trucks), and nearly doubled productivity while reducing errors. Overtime has been vastly reduced, and Ecentria implemented a hiring freeze this past spring that has the company operating at its lowest headcount in 10 years. Batt says he expects to see about $320,000 a year in labor savings as a result of the changes.
“Just going from [a pick rate of] 56 to 91, as an average, is crazy,” Batt explains. “We’re seeing it in our budgets—and it’s all because of these efficiencies.”
NEXT STEPS
Leaders from both companies note that the steps Ecentria is taking today are merely precursors to larger changes, which will include a new DC network design and large-scale DC automation. Plans are to build a DC in the Midwest by 2025—as part of a single or two-DC design, which is still to be determined—that will feature an automated storage and retrieval system (AS/RS), picking robots, and advanced conveyor systems designed to optimize “every aspect of the fulfillment process, from receiving to putaway to shipping,” according to Alpine. Batt says the AS/RS will be the centerpiece of the project and is expected to pay for itself within five to seven years of implementation.
For Batt and his colleagues, the moves can’t come soon enough—but in the meantime, they say they will continue to implement projects that target the “low-hanging fruit” across Ecentria’s current operations in order to make further improvements. And they say they’re making far more progress than if they’d undertaken the analysis by themselves.
“We didn’t have to hire Alpine [for this project]. We could have done it all on our own, but it would have taken us well over a year and I don’t know if we would have gotten the same data,” Batt explains. “And the thing is, we’re still looking at the data and finding things that can help. This whole project has been enlightening. When you work with a company that doesn’t know everything about your [operations], they ask questions you wouldn’t normally ask yourself—and that really helps.”
Consulting firm Accenture has taken another step to bulk up its supply chain advisory capabilities, announcing Monday that it has acquired Allitix, a California-based consulting and technology company specializing in Anaplan solutions with capabilities across financial planning and analysis, sales performance management, and supply chain.
Anaplan is a Florida provider of corporate performance management (CPM) systems, which it defines as enterprise cloud software that empowers organizations to see, plan, and lead better business outcomes by aligning their strategic objectives and resources.
Allitix provides tailored Anaplan-based solutions across finance, sales, supply chain, and human resources functions, with specific competencies in the manufacturing, consumer, technology, media and telecom, and financial services industries.
“Demand for connected enterprise planning is on the rise, given its ability to unlock business value and spur total enterprise reinvention,” David Leckstein, senior managing director and lead, Americas Technology at Accenture, said in a release. “Allitix’s highly skilled talent, deep domain expertise, and agile approach to implementation complements our broader digital capabilities and further expands our ability to deliver integrated enterprise planning transformations for our clients that drive better, faster insights and bottom-line value.”
Terms of the deal were not disclosed, but Accenture said that the acquisition adds 73 employees, including over 60 Anaplan functional and technical professionals to Accenture Technology in North America, with expertise across solution architecture, model building, integration, and data management.
Terms of the acquisition were not disclosed, but Mode Global said it will now assume Jillamy's comprehensive logistics and freight management solutions, while Jillamy's warehousing, packaging and fulfillment services remain unchanged. Under the agreement, Mode Global will gain more than 200 employees and add facilities in Pennsylvania, Arizona, Florida, Texas, Illinois, South Carolina, Maryland, and Ontario to its existing national footprint.
Chalfont, Pennsylvania-based Jillamy calls itself a 3PL provider with expertise in international freight, intermodal, less than truckload (LTL), consolidation, over the road truckload, partials, expedited, and air freight.
"We are excited to welcome the Jillamy freight team into the Mode Global family," Lance Malesh, Mode’s president and CEO, said in a release. "This acquisition represents a significant step forward in our growth strategy and aligns perfectly with Mode's strategic vision to expand our footprint, ensuring we remain at the forefront of the logistics industry. Joining forces with Jillamy enhances our service portfolio and provides our clients with more comprehensive and efficient logistics solutions."
In addition to its flagship Clorox bleach product, Oakland, California-based Clorox manages a diverse catalog of brands including Hidden Valley Ranch, Glad, Pine-Sol, Burt’s Bees, Kingsford, Scoop Away, Fresh Step, 409, Brita, Liquid Plumr, and Tilex.
British carbon emissions reduction platform provider M2030 is designed to help suppliers measure, manage and reduce carbon emissions. The new partnership aims to advance decarbonization throughout Clorox's value chain through the collection of emissions data, jointly identified and defined actions for reduction and continuous upskilling.
The program, which will record key figures on energy, will be gradually rolled out to several suppliers of the company's strategic raw materials and packaging, which collectively represents more than half of Clorox's scope 3 emissions.
M2030 enables suppliers to regularly track and share their progress with other customers using the M2030 platform. Suppliers will also be able to export relevant compatible data for submission to the Carbon Disclosure Project (CDP), a global disclosure system to manage environmental data.
"As part of Clorox's efforts to foster a cleaner world, we have a responsibility to ensure our suppliers are equipped with the capabilities necessary for forging their own sustainability journeys," said Niki King, Chief Sustainability Officer at The Clorox Company. "Climate action is a complex endeavor that requires companies to engage all parts of their supply chain in order to meaningfully reduce their environmental impact."
Supply chain risk analytics company Everstream Analytics has launched a product that can quantify the impact of leading climate indicators and project how identified risk will impact customer supply chains.
Expanding upon the weather and climate intelligence Everstream already provides, the new “Climate Risk Scores” tool enables clients to apply eight climate indicator risk projection scores to their facilities and supplier locations to forecast future climate risk and support business continuity.
The tool leverages data from the United Nations’ Intergovernmental Panel on Climate Change (IPCC) to project scores to varying locations using those eight category indicators: tropical cyclone, river flood, sea level rise, heat, fire weather, cold, drought and precipitation.
The Climate Risk Scores capability provides indicator risk projections for key natural disaster and weather risks into 2040, 2050 and 2100, offering several forecast scenarios at each juncture. The proactive planning tool can apply these insights to an organization’s systems via APIs, to directly incorporate climate projections and risk severity levels into your action systems for smarter decisions. Climate Risk scores offer insights into how these new operations may be affected, allowing organizations to make informed decisions and mitigate risks proactively.
“As temperatures and extreme weather events around the world continue to rise, businesses can no longer ignore the impact of climate change on their operations and suppliers,” Jon Davis, Chief Meteorologist at Everstream Analytics, said in a release. “We’ve consulted with the world’s largest brands on the top risk indicators impacting their operations, and we’re thrilled to bring this industry-first capability into Explore to automate access for all our clients. With pathways ranging from low to high impact, this capability further enables organizations to grasp the full spectrum of potential outcomes in real-time, make informed decisions and proactively mitigate risks.”
According to New Orleans-based LongueVue, the “strategic rebranding” brings together the complementary capabilities of these three companies to form a vertically integrated flexible packaging leader with expertise in blown film production, flexographic printing, adhesive laminations, and converting.
“This unified platform enables us to provide our customers with greater flexibility and innovation across all aspects of packaging," Joe Piccione, CEO of Innotex, said in a release. "As we continue to evolve and adapt to the changing needs of the industry, we look forward to delivering exceptional solutions and service."