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.
As manufacturing and retail organizations seek to streamline operations, many business leaders are homing in on the loading dock as an area to improve efficiency. After all, the smooth movement of materials throughout a facility begins and ends with efficient loading and unloading, making the dock an ideal place to apply advancing equipment and technology.
The next opportunities in dock efficiency include improving access to trailers, which can eliminate bottlenecks in getting products in and out the door; implementing better safety controls to improve the speed and reliability of dock safety systems; and automating processes throughout the warehouse to alleviate congestion on the loading dock. All of these steps can add up to considerable savings at the point of material transfer. Here's a look at each area.
ENSURE PROPER ACCESS
Walt Swietlik, director of customer relations and sales support for dock equipment maker Rite Hite, says the first step in planning a more efficient dock is making sure you have proper access to the trailers you're loading and unloading—that is, ensuring that your dock is designed for the safe, secure, and efficient transfer of products in and out of the trailers. Although that might sound pretty basic, many operations fall short of that standard.
There can be many reasons for that. As one example, dock doors present a problem in many buildings—especially older ones, where doors may be narrower and shorter than the trailers that are backing into them.
"An overhead door that is too short or too narrow is an instant bottleneck to the proper transfer of product," Swietlik explains. "Along with the efficiency issues come product damage issues and safety concerns."
Building new doors that are taller and wider than the trucks and trailers being serviced eliminates those bottlenecks, allowing for a smoother loading and unloading process. Dock seals and shelters have also improved in recent years, making the installation of new, better-fitting doors even more attractive, Swietlik adds. In the past, enclosures designed to allow full access to trailers did not provide the tightest seal around the dock, he says, allowing heated or cooled air to escape and leaving workers, equipment, and products exposed to the elements. Some companies were hesitant to sacrifice energy efficiency and employee comfort in the name of process efficiency. Today's enclosures offer a better seal, eliminating that trade-off.
"Improvements in [enclosure] technology over the last three to five years have allowed customers to have their cake and eat it too—full access to the backs of trucks and trailers with minimal 'white space' around the door opening and the back of the trucks and trailers," Swietlik says.
MAKE SAFETY A TOP PRIORITY
For many, the next opportunities come from installing faster, more reliable safety equipment.
As technology improves, the steps required to activate loading dock safety systems are reduced. Push-button equipment is a prime example, Swietlik says, as it improves the speed and reliability of safety processes. For example, a hydraulic or push-button dock leveler is activated automatically with the push of a button, in contrast to a mechanical dock leveler that has to be put into place using a chain. He says push-button equipment is fast becoming the norm on loading docks.
The next evolution is interlock or sequence control systems, in which safety measures are mutually dependent—that is, operators can't accomplish B without first accomplishing A. Such technology solves problems that can occur when workers take shortcuts as a way to get the job done faster—for instance, not using a dock lock on smaller loads, figuring that the chances are slim a truck will pull away in the time it takes to unload just a couple of pallets. That sounds appealing until you start compromising safety, which will negate any time savings in the long run.
"Interlocks force a company-specified sequence of operation that, when used on a regular basis, will lead to improved efficiencies," says Swietlik. "For probably 98 percent of clients, that's what they are moving toward. That is what many would consider an efficient dock in today's world."
AUTOMATE FOR SUCCESS
Automation is a buzzword across the industrial spectrum, and for good reason: Automated processes can provide the ultimate in efficiency, safety, and productivity. Today, automated trailer loading—via AGVs (automated guided vehicles) that use laser and sensor technology—is a case in point. AGVs help increase accuracy and reduce staffing requirements because fewer people are needed on the dock. John Clark of Dematic Egemin, a global logistics and material handling systems provider that makes AGVs for truck loading, says trailer loading in particular is gaining more attention from customers that have realized accuracy and efficiency gains from using AGVs elsewhere in the facility.
"Customers are saying, 'We've improved everywhere else, where can we go now?'" says Clark, who is the company's director of marketing. He cautions, however, that automated trailer loading is more complex than processes like automated picking, which means different types of AGVs may be required. For one thing, AGVs used on the loading dock must be more robust, often incorporating a higher level of sensor technology in order to adjust the path of the vehicle into the trailer. They also need to be more durable, as they don't always follow a smooth path but may have to go up and over door plates, for instance. Though it's a different type of machine, efficiency is still the goal.
"Any time you have automation, what you're trying to do is remove human touches," Clark explains. "If you can remove touches within your supply chain, it will increase accuracy and throughput, and provide a more complete solution."
Matthew Butler, director of solution strategy for retail and supply chain solutions company JDA Software Group, emphasizes the need to view automation from an even broader perspective. He points to automated case picking as a way to improve movement through the facility and alleviate congestion on the loading dock.
High-volume case-pick operations such as those found in grocery and retail DCs are a good example. In such environments, automated case picking can produce shipment-ready pallets by anticipating stacking requirements and supporting in-process palletization/wrapping of the case-pick pallets for stability. At a lower cost of entry, Butler says, many companies are looking to leverage well-established voice-activated technologies for this purpose. He adds that augmented reality is an emerging technology that is garnering interest, too—and one that today can drive efficiency and accuracy during picking, but tomorrow may provide more direct instruction during pallet-building.
Automation in all its forms is one of the hottest areas in industrial settings, so it's no surprise the loading dock is benefiting from it as well. And when considered alongside more traditional methods of improving efficiency at the dock, it leaves supply chain managers with myriad opportunities to make headway.
"Companies are constantly looking at where they can [remove costs] next," says Clark. "They need to figure out how to maintain a competitive advantage. This is a good way to do that."
Supply chain planning (SCP) leaders working on transformation efforts are focused on two major high-impact technology trends, including composite AI and supply chain data governance, according to a study from Gartner, Inc.
"SCP leaders are in the process of developing transformation roadmaps that will prioritize delivering on advanced decision intelligence and automated decision making," Eva Dawkins, Director Analyst in Gartner’s Supply Chain practice, said in a release. "Composite AI, which is the combined application of different AI techniques to improve learning efficiency, will drive the optimization and automation of many planning activities at scale, while supply chain data governance is the foundational key for digital transformation.”
Their pursuit of those roadmaps is often complicated by frequent disruptions and the rapid pace of technological innovation. But Gartner says those leaders can accelerate the realized value of technology investments by facilitating a shift from IT-led to business-led digital leadership, with SCP leaders taking ownership of multidisciplinary teams to advance business operations, channels and products.
“A sound data governance strategy supports advanced technologies, such as composite AI, while also facilitating collaboration throughout the supply chain technology ecosystem,” said Dawkins. “Without attention to data governance, SCP leaders will likely struggle to achieve their expected ROI on key technology investments.”
The British logistics robot vendor Dexory this week said it has raised $80 million in venture funding to support an expansion of its artificial intelligence (AI) powered features, grow its global team, and accelerate the deployment of its autonomous robots.
A “significant focus” continues to be on expanding across the U.S. market, where Dexory is live with customers in seven states and last month opened a U.S. headquarters in Nashville. The Series B will also enhance development and production facilities at its UK headquarters, the firm said.
The “series B” funding round was led by DTCP, with participation from Latitude Ventures, Wave-X and Bootstrap Europe, along with existing investors Atomico, Lakestar, Capnamic, and several angels from the logistics industry. With the close of the round, Dexory has now raised $120 million over the past three years.
Dexory says its product, DexoryView, provides real-time visibility across warehouses of any size through its autonomous mobile robots and AI. The rolling bots use sensor and image data and continuous data collection to perform rapid warehouse scans and create digital twins of warehouse spaces, allowing for optimized performance and future scenario simulations.
Originally announced in September, the move will allow Deutsche Bahn to “fully focus on restructuring the rail infrastructure in Germany and providing climate-friendly passenger and freight transport operations in Germany and Europe,” Werner Gatzer, Chairman of the DB Supervisory Board, said in a release.
For its purchase price, DSV gains an organization with around 72,700 employees at over 1,850 locations. The new owner says it plans to investment around one billion euros in coming years to promote additional growth in German operations. Together, DSV and Schenker will have a combined workforce of approximately 147,000 employees in more than 90 countries, earning pro forma revenue of approximately $43.3 billion (based on 2023 numbers), DSV said.
After removing that unit, Deutsche Bahn retains its core business called the “Systemverbund Bahn,” which includes passenger transport activities in Germany, rail freight activities, operational service units, and railroad infrastructure companies. The DB Group, headquartered in Berlin, employs around 340,000 people.
“We have set clear goals to structurally modernize Deutsche Bahn in the areas of infrastructure, operations and profitability and focus on the core business. The proceeds from the sale will significantly reduce DB’s debt and thus make an important contribution to the financial stability of the DB Group. At the same time, DB Schenker will gain a strong strategic owner in DSV,” Deutsche Bahn CEO Richard Lutz said in a release.
Transportation industry veteran Anne Reinke will become president & CEO of trade group the Intermodal Association of North America (IANA) at the end of the year, stepping into the position from her previous post leading third party logistics (3PL) trade group the Transportation Intermediaries Association (TIA), both organizations said today.
Meanwhile, TIA today announced that insider Christopher Burroughs would fill Reinke’s shoes as president & CEO. Burroughs has been with TIA for 13 years, most recently as its vice president of Government Affairs for the past six years, during which time he oversaw all legislative and regulatory efforts before Congress and the federal agencies.
Before her four years leading TIA, Reinke spent two years as Deputy Assistant Secretary with the U.S. Department of Transportation and 16 years with CSX Corporation.
Serious inland flooding and widespread power outages are likely to sweep across Florida and other Southeast states in coming days with the arrival of Hurricane Helene, which is now predicted to make landfall Thursday evening along Florida’s northwest coast as a major hurricane, according to the National Oceanic and Atmospheric Administration (NOAA).
While the most catastrophic landfall impact is expected in the sparsely-population Big Bend area of Florida, it’s not only sea-front cities that are at risk. Since Helene is an “unusually large storm,” its flooding, rainfall, and high winds won’t be limited only to the Gulf Coast, but are expected to travel hundreds of miles inland, the weather service said. Heavy rainfall is expected to begin in the region even before the storm comes ashore, and the wet conditions will continue to move northward into the southern Appalachians region through Friday, dumping storm total rainfall amounts of up to 18 inches. Specifically, the major flood risk includes the urban areas around Tallahassee, metro Atlanta, and western North Carolina.
In addition to its human toll, the storm could exert serious business impacts, according to the supply chain mapping and monitoring firm Resilinc. Those will be largely triggered by significant flooding, which could halt oil operations, force mandatory evacuations, restrict ports, and disrupt air traffic.
While the storm’s track is currently forecast to miss the critical ports of Miami and New Orleans, it could still hurt operations throughout the Southeast agricultural belt, which produces products like soybeans, cotton, peanuts, corn, and tobacco, according to Everstream Analytics.
That widespread footprint could also hinder supply chain and logistics flows along stretches of interstate highways I-10 and I-75 and on regional rail lines operated by Norfolk Southern and CSX. And Hurricane Helene could also likely impact business operations by unleashing power outages, deep flooding, and wind damage in northern Florida portions of Georgia, Everstream Analytics said.
Before the storm had even touched Florida soil, recovery efforts were already being launched by humanitarian aid group the American Logistics Aid Network (ALAN). In a statement on Wednesday, the group said it is urging residents in the storm's path across the Southeast to heed evacuation notices and safety advisories, and reminding members of the logistics community that their post-storm help could be needed soon. The group will continue to update its Disaster Micro-Site with Hurricane Helene resources and with requests for donated logistics assistance, most of which will start arriving within 24 to 72 hours after the storm’s initial landfall, ALAN said.