AI is transforming the supply chain. The supply chain can help transform AI.
Applying artificial intelligence to the supply chain will help make it more efficient and effective, but first the supply chain must help build the infrastructure needed for large-scale AI implementations.
On February 7, Openai CEO Sam Altman issued the following call on X:
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A day later, the Wall Street Journal reported that Altman was in discussions with potential investors, seeking as much as $5 to $7 trillion to boost chip production to a level that would further accelerate the growth of his company and the overall AI sector. A lot of attention since then has (unsurprisingly) been on the headline investment figure, which—to put it in shipping industry terms—would represent around five times the estimated value of the global merchant vessel fleet today.
The logistics and supply chain sector has seen many discussions around how AI can impact our industry, particularly in optimizing processes and flows, improving forecasting and data analysis, and providing intelligent operating platforms for new advanced technologies. Less attention has arguably been paid to the supply chain challenges that lie in the way of creating the infrastructure to support AI implementation, Altman’s announcement shines a light on three major trends and challenges that are fundamentally reshaping our industry on both of these fronts:
1. The “great games” of the 21st century
We are living in an era of intense geopolitical competition, with the U.S., China, and the EU, in particular, jostling for position and advantage as the three “centers of gravity” of global trade. In strategic sectors such as electric vehicles (EVs) and batteries, solar power and green energy, and semiconductors, we are seeing national governments legislate and allocate investment to try to protect their domestic workers and industries while transitioning to the areas that will guarantee economic growth in the future.
We are also already seeing shifts in semiconductor production as part of a nearshoring trend. Altman’s call for investment in chip production will resonate with a U.S. government that is acutely aware of the capabilities that its rivals are building up at pace and is concerned about falling behind, as well as future risks to national security. But the fundamental laws of economics and competitive advantage indicate that trade will continue to flow from markets with lower labor and production costs (albeit at varying levels). As the world swings between the interdependency of global supply chains and spikes in domestic production and protectionism, logistics companies will need to provide the flexibility, visibility on material flows, and expertise on capacity management and network design that their customers need to respond in real time.
2. The focus on resilience
Altman argued in his X post that massive-scale AI infrastructure and a resilient supply chain are crucial to economic competitiveness. Since the disruption that the pandemic unleashed on global supply chains, our industry has become a more regular feature on corporate board room agendas, and resilience has become arguably the No. 1 priority in those discussions.
Resilience in the supply chain can come in many forms—adding redundancy, planning contingency routings and capacity, redesigning networks to be closer to customers or production sites, shifting between modes of transport, maintaining higher stock levels, diversifying supply sources, or simply increasing real-time visibility. Logistics companies are best positioned to identify the approaches that achieve resilience with an optimal balance of cost, service reliability, and quality.
As with any journey into uncharted waters, any attempt to supercharge chip production will undoubtedly encounter bumps and knocks, challenging everyone on the ship to pull together and respond. True supply chain resilience for a project of this scale will require the type of adaptable and flexible approach that our industry has perfected over the last four to five years, supported by the very technologies that it is working to advance.
3. The sustainability paradox
To achieve the Paris climate targets and our own net zero ambitions, the logistics industry needs to see further step changes in technology. AI will play a decisive role in this technological evolution, helping us discover new green solutions and materials that reduce or eliminate emissions, as well as to generate insights that accelerate the development of EVs, sustainable fuels, and other nascent clean technologies.
One of the major criticisms leveled against Altman’s plan has been that the energy and other resources needed to support such a gargantuan level of chip production and processing power for AI will be damaging for the environment. In the shorter-term, the supply chain—through its efficiency and optimization measures—offers one of the most effective levers to mitigate the environmental footprint of this kind of AI infrastructure expansion. In the longer term, paradoxically, a truly zero-emissions supply chain will be dependent on the kind of breakthrough that only an expansion like this can provide.
Whether or not the final investment figure that is required to realize Altman’s ambitious vision is as much as $7 trillion (he even discussed revising it up to $ 8 trillion in a playful post later in the month), it is clear that the logistics and supply chain sector would play a critical role in making it a success. We are already seeing the potential of AI to transform our industry. By the same virtue, logistics can play an essential role in any large-scale, transformational effort to expand AI.
Forklift batteries power the fleets at the center of facility operations. If your batteries are well-maintained, your team is empowered to drive efficient, sustainable, and productive operations. Given your forklift battery can also be as much as 30% of your forklift’s total cost, taking care of it is crucial not just for its longevity and efficiency, but in creating a safe, productive, and cost-effective facility. Improper battery care can create a financial strain on your company along with plenty of safety hazards.
Pulling from decades of experience helping some of the largest and busiest facilities across the country with their power management challenges, I’m sharing the most common mistakes that can shorten your forklift battery’s life by up to 60% or one to three years.
Most common forklift power system design mistakes
Four of the most common mistakes are associated with how a company designs its forklift power system, which includes not just the battery but also chargers and changers.
Not considering your batteries as part of a power system. Your system design should be based on more than just the forklift’s battery specification. The best power systems are built after an assessment of your facility’s applications and workflows, such as when and how batteries are watered. To drive higher uptimes and longer battery life, companies need to optimizing not just for everything they do today but also consider their future plans.
Using the wrong charger. Many companies, trying to save a little money, switch to new batteries but use old, mismatched chargers. For example, they change their batteries every five years, but only buy new chargers every 10-20 years. While the battery technology has improved, the charger (the intelligence) hasn’t, and that means they may not be getting the most out of their new battery equipment as far as charge profiles and efficiency. This shortens battery life, drives up power bills, and in the long term, ends up being more expensive than simply buying new chargers.
Having malfunctioning chargers. Chargers are designed to provide power to batteries up until 100% capacity. When a new model of charger is unable to provide full power, it is often due to malfunctioning power modules or communications issues between battery modules and the charger itself. Additionally, older style high frequency (HF), silicon controlled rectifier (SCR), and Ferro chargers may experience output capacity drop off due to malfunctioning fuses, diodes, SCRs, insulated-gate bipolar transistors (IGBTs), and capacitors. If left unchecked, the reduced output of these chargers will cause batteries to sulfate and ultimately fail.
Not planning a charging standard operating procedure (SOP) in advance. Most companies charge when it’s best for the operator, but it’s important to set up a charging schedule that also takes into account the needs of your facility and your batteries. A schedule that accommodates both the operator’s and the battery’s needs will lengthen lifespan tremendously. This requires regular monitoring to ensure compliance with the charging SOP. If this is not maintained, batteries will often fail due to the lack of consistent charging.
Most common forklift power maintenance mistakes
The remaining common mistakes focus on how a company maintains its batteries and chargers.
Not implementing an equalization schedule. Lead acid batteries require an equalization charge on a regular basis to maintain their long-term health and capacity. Build a plan for equalization into your battery charger plug-up times, then set those schedules into your chargers.
Not watering correctly. Batteries need to be watered on a schedule. Ideally, batteries are watered right after charging to avoid electrolyte overflow issues, chemical spills, and degradation. Proper water levels ensure electrolytes stay in balance and batteries don’t overheat. These expensive mistakes add up over time.
Having a malfunctioning single-point watering system. Single-point watering systems are employed for labor savings in the weekly watering of batteries. While useful, these systems are subject to failure due to abuse and just normal wear and tear. Oftentimes, these systems will fail at individual watering points and are not noticeably malfunctioning. This will lead to unequal watering and ultimately a series of battery failure points over time. This too must be regularly monitored for proper function.
Not responding swiftly to maintenance issues. It’s important to set up a maintenance schedule so you can ensure every battery and charger gets attention when it should. Early identification of issues, paired with course correction, can nip issues in the bud, greatly extending the life of your equipment.
Your forklift batteries are the preservers of power at your facility. If properly cared for, they power smooth and reliable operations that keep downtime at bay. The unexpected can and will happen every single year—that’s just a part of business. But the expected, that is something we can prepare for. Companies that take a proactive approach to their power and their facility’s unique power are poised to take on any challenge with an uninterrupted power supply.
More than ever before, supply chain businesses are faced with dynamic conditions due to consumer buying trends, supply chain disruptions, and upheaval caused by other outside forces including war, political instability, and weather conditions. Supply chain companies, including warehouses, must be able to pivot quickly and make changes to operational processes without waiting for weeks or months.
As a result, warehouse management systems (WMS) need to be agile enough to make changes to operational processes and turn on a dime in today’s fast-paced world. Traditional warehouse management systems, however, are rigid and complex, not easy to customize or change. In addition, integrations—especially to modern technologies such as the internet of things (IoT), artificial intelligence (AI), and machine learning—can be problematic.
Furthermore, traditional warehouse management systems depend on the expertise, experience, and knowledge of software developers to hand code applications. This type of technical labor is costly and can be hard to find, leading to dependence on the WMS software developer. Whenever changes or customizations to traditional WMS are needed, experienced software developers are needed, and this effort is usually time-consuming and expensive.
One solution is to consider a warehouse management system built on a low-code application platform (LCAP). Unlike traditional warehouse management systems, software applications built on LCAPs are more flexible, adaptable to meet changing business requirements, easier to integrate, and scalable.
[subhead] What are low-code application platforms?
LCAPs give users a visual, drag-and-drop interface that allows them to create applications by assembling prebuilt components, integrations, and templates. This simplification of the software development process facilitates faster prototyping, iteration, and deployment.
It also enables application development to be open to nontechnical users who may have significant experience, knowledge, and expertise in warehouse operations. Nontechnical users can work alongside IT resources to automate workflows, create business rules, process flows, and data models. To do this, visual tools are used to replace the need for writing complex code. Event-driven triggers and actions are leveraged to automate repetitive tasks and integrate with other systems. This can lead to better alignment of operational processes within the warehouse.
Low-code application platforms may also include features to promote team collaboration. Multiple users can work on the same project simultaneously, and version control mechanisms help to ensure that changes can be tracked and managed efficiently. In case it becomes necessary, rollback can be used to return to previous versions.
Low-code application platforms include tools for deployment, hosting, and maintenance. Applications can be deployed by users to a variety of environments with only minimal configuration. Maintenance and updates can be handled within the platform, and automated testing and deployment pipelines are frequently used.
Seven benefits of LCAPs
There are many benefits to using an LCAP as opposed to a traditionally coded warehouse management system, including:
1. Adaptability and ability to customize. LCAPs provide significant value for a WMS due to the speed at which applications, features, and customizations can be developed and deployed. This can help to ensure higher customer satisfaction and the ability to adapt more rapidly to supply chain disruptions, changes in demand, and advances in technology.
LCAPs help solve the challenges faced by a rigid traditional WMS by making the WMS faster and easier to tailor to meet customer or business requirements without high-priced IT resources. This can translate into time and labor savings for the warehouse operator.
2. Integration. Atraditional WMS often does not have the capability of integrating with cloud-based services, limiting the ability for it to take advantage of the cost benefits, flexibility, and scalability of cloud computing. In addition, it is often challenging for traditional warehouse management systems to integrate with automation technologies including robotics, autonomous guided vehicles (AGVs), conveyor systems, and other technologies.
Because LCAPs leverage built-in connectors as well as application programming interfaces (APIs) that facilitate integration with other systems, integration is seamless, ensuring a more efficient, cohesive ecosystem. This ease of integration can aid in unifying data across different systems to improve decision-making and information visibility.
3. Scalability. As a business grows, warehouse operations typically become more complex. This complexity typically leads to the need to handle increased volumes of data and more complicated workflows as well as expanded warehouse operations. This can present challenges for traditional warehouse management systems.
Low-code application platforms are able to scale more easily to handle increased volumes of data, more operational complexity, and additional functionality without a complete overhaul of the WMS. It is faster and easier to make quick adjustments on a WMS built on an LCAP. The system can easily scale up or down to handle new business requirements, changes in demand, and much more.
4. Security. Older warehouse management systems may lack the advanced security features required to protect sensitive data from cyber-attacks. Modern low-code application platforms typically include robust security measures to ensure that data is protected.
5. Up-to-date user interface and user experience. The outdated user interfaces commonly found with many older warehouse management systems can hamper productivity and lead to errors. WMS users need to have a streamlined user interface, designed to focus their attention on operations, without distractions.
Using a WMS built on an LCAP can improve the user experience and boost productivity. This is because LCAPs often feature intuitive, user-friendly interfaces that enhance the overall user experience. This makes it easier for warehouse workers to navigate the software, reducing errors and frustration.
6. Real time visibility. Older warehouse management systems may not be able to provide visibility into warehouse operations, inventory levels, and order status in real time. This can reduce the responsiveness to customer and market demands and delay decision-making.
One advantage of using a WMS built on an LCAP is that it can be integrated to IoT devices and sensors. This will enable the capture of real-time data on inventory levels, environmental conditions within the warehouse, equipment status, and more.
7. Data management. Today, with the popularity of online shopping, a WMS needs to be able to handle a high volume of orders with many individual items per order. A traditional WMS, which is designed to handle goods by the case or pallet, rather than by the individual saleable unit, may have performance issues, such as with data lock up or data retrieval, when handling large volumes of data.
Using a WMS built on an LCAP can facilitate the integration of multiple data sources into one unified platform, improving data accuracy and consistency. All data is available in one place. In addition, there are built-in tools for data validation, cleansing, and governance. This helps to ensure high data quality, essential for reliable real-time data visibility.
Transformative potential
Technology continues to advance. Software development continues to evolve. By taking advantage of low-code application platforms to simplify the software development process, supply chain professionals can ensure that they are able to keep up with these changes.
LCAPs enable rapid development, customization, and deployment of software applications, enabling businesses to respond to changing market conditions and technological advances. The result is notable cost and time savings, increased efficiency, and more effective operations. Using LCAPs, companies can take advantage of increased flexibility, scalability, and adaptability to be more competitive, drive operational excellence, and support growth.
In a male-dominated industry like supply chain technology, there is a growing opportunity for women to lean in and contribute their unique skills and perspectives. Research consistently demonstrates that diverse teams outperform less diverse ones, emphasizing the importance of inclusivity and gender diversity within the industry.
According to research by McKinsey & Company, companies with more than 30% female executives are more likely to outperform companies with only 10% to 30% of women leaders. The study also found more gender-diverse companies outperform the rest by 48%.
In light of this research, every supply chain company should take a moment to examine how to better diversify its leadership team and enable women to advance in the industry.
Strengthen the university-to-supply-chain pipeline
With no end in sight to the supply chain talent crunch, this protracted crisis presents an opportunity for more women to jump into the supply chain field. At Optilogic, we have found working with universities with supply chain management programs a great way to encourage budding female practitioners as well as create a future talent pipeline.
We connect with local University of Michigan students to teach them about supply chain design and get them involved in hands-on testing, training, and networking events. I am also working on a joint initiative with the female leader at the University of Michigan Ross Master of Supply Chain Management program on a STEM panel for women in supply chain.
Promote clarity and dispel bias about supply chain careers
Even in 2024 misconceptions and biases exist about supply chain roles for women. Women may perceive supply chain roles as being not well suited for females, especially some front-line roles in logistics and warehousing where women are underrepresented in traditionally male-dominated roles. Conscious or unconscious bias may exist with hiring managers as well.
Employers can also consider improvements to supply chain roles to make them more flexible and family-friendly. For women in the workforce, especially those with children, benefits like flexible hours and roles that allow them to balance work and other responsibilities can help address real barriers to entry.
Practical ways you can support women in supply chain today
Below are three ways the industry can help support female leaders.
Create a personal “board of directors.” Support female executives in the supply chain industry to move ahead in their careers by enabling them to cultivate a personal board of directors. This may consist of a few individuals who can offer advice, mentorship, support, and diverse viewpoints. These mentors can be both men and women who are inside or outside of the industry and can create a well-rounded network for personal and professional growth.
Join a women leaders platform. Organizations, platforms and groups designed to provide networking opportunities, mentorship, and skill-building resources are another great opportunity for female executives in the supply chain industry. For example, the Optilogic Women Leaders platform empowers the next generation of female leaders to thrive, leading to a more diverse and fair work environment.
Pass it forward. Female executives in the supply chain industry can also advance the cause by sharing their experiences with other professionals and supporting educational programs that promote women leaders. They can also attract young women to the supply chain industry by promoting their successes and encouraging them to pursue careers in the industry. Another simple yet effective way to support other women is to stand up for one another in meetings, give each other the floor, and promote others to encourage high potential female leaders.
It’s important for everyone in the supply chain industry to support women who are ready to rise in the ranks through the recruitment and development of female executives. Doing so will help ensure companies remain competitive by harnessing the power of gender-diverse teams.
In a rapidly evolving business landscape, the spotlight on supplier compliance has intensified, according to the “QIMA 2024 Q1 Barometer Report,” which is based on a survey of more than 800 businesses within the international supply chain as well as QIMA’s own internal data. This scrutiny can include making sure suppliers meet various requirements and policies around social issues, forced labor, structural integrity, traceability, environmental goals, scope-3 emissions, and more.
Nearly two-thirds of respondents to QIMA’s survey acknowledged the growing importance of compliance, with 70% of businesses saying they factor at least one ESG (environmental, social, and governance) element into their sourcing decisions. However, as we peel back the data, a stark reality emerges: Despite the commitment to ESG compliance, actual progress has been slow, with 25% of respondents saying that inspected supplier factories require urgent improvement.
As businesses embrace the multifaceted dimensions of ESG considerations, an unsettling gap emerges between intention and execution. How do these intentions materialize on the ground, and why does the alleged emphasis on ethical sourcing fall short?
Unveiling discrepancies
The field audit data paints a detailed picture of the challenges in ethical compliance. A quarter of factories audited received a concerning “red” ranking, indicating a need for immediate remediation. A substantial 67% of the issues identified center around health and safety and working hours and wages.
While many of these challenges are not new and cannot be tackled through a single audit, there is an even bigger hurdle to fully addressing ethical risk in supply chains: a lack of supply chain visibility. Only 16% of businesses claim to know all of their suppliers across all tiers, indicating that a majority of companies are in the dark when it comes to how the goods within their supply chain are manufactured and procured. This visibility gap can be a red flag for disparity between ESG intentions and actual implementation.
An unfortunate consequence of focusing audits at strategic tier-1 suppliers is that this practice creates a knowledge gap. Not including all tier-1 suppliers in your audit program can leave a company with unknown—and therefore unmanageable—risk. Companies also leave themselves open to potential material risks and impacts that could affect their ESG strategy when they do not engage with lower-tier suppliers. While tier-1 suppliers might be more inclined to meet compliance standards, smaller suppliers may maintain a wide range of ESG risks yet to be uncovered due to lack of an audit. The greater problem with working with less audited factories underscores a tremendous issue: not knowing what you don't know may be the biggest risk.
Navigating the crossroads
Reviewing these findings, the implications for businesses become clear: Aligning ESG strategies with ground-level realities, enhancing supply chain visibility, and tailoring ethical compliance considerations are imperative. The data within this survey is not simply a revelation of challenges but a call-to-action for businesses to bridge the gap between intention and execution in their ethical sourcing programming.
The intricacies of ethical compliance underscore tremendous challenges and opportunities. By understanding the correlation between sourcing region maturity and compliance, businesses can develop a more sustainable future. It’s time to acknowledge the challenges and actively engage in forging a path toward ethical and responsible sourcing practices.
In the manufacturing industry, enterprises are increasingly examining their production processes and systems to improve sustainability. Specifically, efforts to minimize waste, pollution, and energy consumption are not only growing in popularity with consumers but businesses as well. These efforts also improve operational efficiency, increase a company’s competitive advantage, strengthen brand reputation, and facilitate organizations’ adherence to regulatory guidelines.
Success in achieving these goals will depend on smart manufacturing, which uses advanced technologies to automate business processes, track information throughout product lifecycle, and provide advanced visibility and quality control to enterprise operations. For example, as sustainability is prioritized across the supply chain, organizations will require proper metrics to ensure stakeholders are meeting sustainability goals. Smart manufacturing technologies will help ensure that companies are accurately measuring and tracking their progress against these metrics.
Regulations increase pressure for sustainability metrics
One factor driving the need for manufacturers to implement sustainability metrics is the increasing number of regulations, both domestic and international, requiring companies to integrate sustainability practices into their business operations. This past year, the International Sustainability Standards Board (ISSB), the global body responsible for developing international reporting requirements, issued two reporting standards requiring companies to disclose material information about sustainability and share specific information on climate risks and opportunities. These standards provide a global baseline for organizations to report climate-related issues and impacts on business operations. Though the standards are not explicitly imposed upon organizations or jurisdictions, they do provide a framework for mandatory and voluntary reporting practices.
Domestically, the Securities and Exchange Commission (SEC) finalized its climate disclosure framework this year, requiring organizations to disclose pollution metrics generated by their company through registration statements and periodic reports . This not only entails greenhouse gas emissions produced by the company’s operations but also indirect emissions, such as energy purchased from utilities.
Similarly, individual states are increasingly enacting legislation that requires companies to report and monitor their sustainability efforts. For example, California recently signed a landmark mandate for the disclosure of corporate carbon dioxide emissions. As the number of regulations grow, organizations become increasingly responsible for creating and meeting sustainability standards.
Business advantage to sustainability measurements
Besides the external factors and pressures motivating organizations to examine the environmental impact of their output, there are also internal factors that rationalize implementing sustainability metrics. For example, brand recognition and competitive advantages are additional arguments that support increased attention to reducing waste production and greenhouse gas emissions, improving materials sourcing, and more. In fact, a recent report highlights that 39% of manufacturers reportedly pursue sustainability goals as a competitive differentiator. Improving sustainability efforts not only promotes more efficient processes and decreases waste but also caters to business and consumer interests of sustainably produced goods.
Furthermore, efforts to improve energy management, carbon offsetting, water conservation, waste reduction, and raw material usage all contribute to cost reduction and increased resilience. As manufacturers implement these measurements into their operations, they are also fortifying operations against disruptions, decreasing costs as materials are upcycled and reused, and uncovering new avenues for efficiency and innovation.
How to accurately measure and improve sustainability in manufacturing
Now, achieving these goals will require a robust data infrastructure that allows manufacturers to aggregate and analyze current performance metrics and connect information across systems and machines. This data infrastructure can be achieved by using manufacturing execution systems (MES) and enterprise resource planning (ERP) systems, quality management systems (QMS), supply chain planning (SCP), and the industrial internet of things (Industrial IoT). The following provides examples of how these systems can help company collect information related to waste production, material usage, and quality control:
Industrial IoT sensors embedded in machinery allow communication between devices to gather insights on equipment performance and provide feedback on machine health. Some can even report on natural resource usage or greenhouse gas emissions emitted during production.
MES can monitor energy consumption across organizations in real-time, identifying idling equipment or excess material usage. They can also monitor equipment health and provide proactive maintenance suggestions to avoid downtime. Recognizing equipment malfunction is critical to sustainability as it reduces potential wasted materials and energy
QMS can provide constant analysis of potential areas for improvement and consistent control over production. As such, they can help eliminate waste and identify defects throughout the manufacturing process.
SCP can forecast demand and inventory, optimize transportation routes, provide sourcing information on potential partners, and facilitate closed-loop systems to recycle products. Accurate forecasting and optimized transportation lead to more efficient material usage and route planning, resulting in lower resource consumption and emission production.
ERP systems can collect data on energy consumption and material utilization. They can also be used to create customized dashboards and reports to follow key performance indicators (KPIs) to assess organization performance against sustainability goals.
By fostering efficient operations and monitoring performance, these technologies allow organizations to improve planning and execution, which helps them to reduce waste and maximize output. The manufacturing systems described above along with advanced technology—such as smart devices, machine learning, artificial intelligence, blockchain and digital twins—provide real-time data that can be placed into predictive models to proactively predict events such as unplanned stoppages and repairs, fluctuations in energy consumption, and material or resource needs. These technologies can also develop simulations to test different scenarios that may help manufacturers decrease certain environmental impacts. They can also provide efficient tracking of products, components, or materials throughout their lifecycle.
A recent survey found that 65% of manufacturers claim that technology plays a significant role in achieving sustainability goals. Managing sustainable manufacturing practices begins with technology that provides data-driven insights. As manufacturers realize that sustainability goals are not just connected to compliance but performance, they will begin to seek out these platforms that monitor waste production, emission reduction, raw material usage, and product quality. In doing so, they will also benefit from the improved efficiency and increased savings that accompany these sustainability goals.