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.”
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.