In our continuing series of discussions with top supply-chain company executives, Loren Swakow discusses changes in the lift truck market, his company’s growth, and the impact of telematics.
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.
Loren Swakow is managing director of Noblelift North America, a China-based forklift manufacturer that hired Swakow in 2016 to bring the brand to the U.S. and Canada. He has since overseen the spinoff of Noblelift Canada into a separate entity with 30 dealers. Noblelift currently has 115 dealers in the United States as well as dealers in Mexico and Colombia.
A life-long Chicagoan, Swakow was president of Scott Lift Truck in Elk Grove Village, Illinois, from 1977 to 2012. He holds a business degree from Carthage College in Wisconsin and an MBA from Northern Illinois University. Swakow is a past president of MHEDA (the Material Handling Equipment Distributors Association) and past president of CITDA (Chicago Industrial Truck Dealers).
Q: How would you describe the current state of the material handling industry?
A: The material handling industry in America continues to flourish. E-commerce requires a lot of products to be moved continuously. We can see our brick-and-mortar stores continue to disappear. Americans are consuming online.
This requires efficient distribution centers. I believe they are driving the market. They need material handling equipment in volume. They require frequent deliveries to keep their stock levels optimum. These trucks coming in are all loaded with material handling equipment as well. The industrial buildings are getting taller to make the most of a smaller footprint. This requires a new style of lift truck that can reach up to 400 inches. This, in turn, requires the owner to buy new equipment. A lift truck that can go up to 400 inches is cheaper than the land to expand to hold extra product.
The wide acceptance of lithium power as the preferred source of energy is driving the market as well. Lithium batteries generally have a 10-year warranty. There are electric trucks that can have 50-degree gradeability. Cleaner, no maintenance, fast charging, opportunity charging, etc. are pushing the electric and internal combustion market to lithium. We are seeing higher and higher capacities as well. With the continual drop in lithium pricing out of China, the lithium lift truck is competing in price with the lead acid truck—we are seeing many cases where lithium can even be less expensive at initial purchase point. Leasing companies see this and are increasing residuals on lithium trucks. A five-year-old lead acid truck needs a battery. A five-year-old lithium truck still has five years of warranty left on the battery.
I feel these two issues—e-commerce and lithium—are keeping material handling growing at a rate faster than the economy.
Q: You have been in the lift truck industry since 1977. What major changes have you seen during your 45-plus years in the business?
A: Some of the biggest changes I’ve seen center on the safety of the driver and the pedestrians in the work area. Blue lights, strobes, headlights, and so forth used to be options. Now they are standard equipment. This helps protect the pedestrian, especially as we move to electric trucks, which are quieter than internal combustion units. The addition of a rear horn button so the driver can sound the horn without having to take his eyes away from the direction of travel is also helping to warn pedestrians of an oncoming vehicle.
Driver safety has been improved greatly as well. Seat belts, including those with ignition lock-out, are common. Speed reduction in turns is standard, reducing rollovers. Speed reduction with forks in the air also helps stabilize the truck. The advancements in safety are removing driver error from the equation and saving lives.
I have also seen the advent of OSHA certification, a justifiable requirement to drive a lift truck. The ergonomics of the lift truck have seen major advances as well. Driver comfort is important. Adjustable steering wheels are standard. Seats have greatly improved too, with multiple settings to adapt to each driver. When I think about the seats we were selling in the 1970s, I wonder how the driver could sit in them for hours at a time. Monitors in the dash now give the driver access to information on the machine’s operating condition.
The second major change I have witnessed would be with electric lift trucks, primarily Class I. We have moved from carbon pile, to contactors, to rectifiers, to solid state—all with the goal of reducing heat production in electric lift trucks and increasing efficiency. Heat is lost energy. The drive motor has seen major improvements as well. From DC to AC, with AC having the ability to put power back to the battery. These new motors also have a very long life span compared to electric motors with carbon brushes.
Electric lift trucks were slowly eating into the market share of internal combustion trucks. Now with the advent of lithium and all its attributes, I expect that replacement of IC trucks by electrics to increase. Lithium is here to stay. We are also seeing higher voltage in lift trucks compared to the 1970s. We have an 80-volt 5,000-pound truck that has twice the voltage of the old 36-volt electric truck. Again, higher voltage is more efficient and has less heat output and longer run times. All of this in a smaller configuration. We are using a lithium iron compound, the most stable and safe compound on the market.
Q: How have telematics and real-time information technologies affected lift truck operations?
A: Information gathering and dissemination has always been an important topic for American business. Telematics came into vogue when the large distribution centers with hundreds of lift trucks needed to keep track of their fleet—not only monitoring the location of the trucks but also tracking critical maintenance and operational information. This can be reviewed in an office without having to inspect the lift truck. This also prevents a lot of major repairs by noting an issue before it becomes crucial. Fleets of lift trucks are expensive. Fleet management is paramount to protect that investment.
With today’s large buildings, you need communication with the driver. Coming back and forth to the office is terribly inefficient. Lift trucks now come with USB ports to power communication devices or tablets, making the drive more efficient. Real-time information sharing between management and the driver promotes efficiency and saves both fuel and time, which translates into money for the owner.
Q: Noblelift has seen tremendous growth in recent years, with sales projected to rise 25% in 2023. To what does your company owe its success?
A: The product is exceptional. Our warranty cost compared to revenue is less than one-half of 1%.
When Noblelift first offered me the job in 2016, I turned it down. I had never heard of Noblelift, and I had a preconceived notion of Chinese quality. They asked me to come over for an interview. After I had personally seen the quality of the workmanship and rigorous inspection processes, I readily accepted the position. I will admit, I was extremely impressed with the quality control and high-tech manufacturing with robotics. I also found out they were building products for many well-respected OEMs, many of which I had represented at one time or another.
Our dealers felt the same way. They would give it a try, as I was offering free returns with no restocking charge. They discovered the same quality and slowly began to embrace the brand. We felt strongly that the brand needed to be promoted, and we have been marketing to achieve that.
China also put a bonus plan in place that promotes our team, so we are all pulling in the same direction. Last year, this amounted to 18% of pay. Morale is good, and financials are shared. We measure ourselves against the previous year’s month. We compare October of 2023 against October of 2022. This format takes cycles out of the comparison and I believe is a good measure of our consistent growth. We have been surpassing the previous year’s month [in terms of performance] on a regular basis for over four years now. With the addition of new products on a regular basis, I expect double-digit growth to continue for years to come.
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]."