Connect with us

Non classé

The Retailer FabFitFun Excels at Logistics

blog

Published

on

The Retailer Fabfitfun Excels At Logistics

FabFitFun Warehouse in Chino, CA

FabFitFun is an interesting retailer with a complex supply chain. They have assembled a set of hardware and software solutions to enable huge surges in shipping. They have been successful enough with their fulfillment capabilities that they are no longer just a direct-to-consumer retailer; they are also a third-party logistics provider.

Forbes.com had a well-written story about them a couple of years ago. “Four times a year, Valerie McKellar waits near her front door, peeking through the blinds and double-checking the FedEx mobile app for status updates on the delivery of her FabFitFun subscription box. When it’s finally dropped off on her porch, she heads to her living room table, one big enough to host each of the products she carefully opens one at a time: A Vera Bradley Compact Organizer. An Alice + Olivia duffle bag. A Short Stories LED indoor planter. ‘It’s just so exciting,” McKellar says. “A lot of people relate it to Christmas and that’s very much true. It feels like it’s this great gift that I’ve given myself.’”

The FabFitFun box includes a selection of full-size products across beauty, fashion, fitness, wellness, home, and tech—delivered each season. FabFitFun members can customize the box based on their preferences, or accept the product selections curated by the company. Members can subscribe annually for $219.99 or seasonally for $69.99/box. The company touts savings of up to 70% per product.

This is an interesting retail niche, but it comes with a supply chain that has huge surges in shipping. Julian Van Erlach, the senior vice president of supply chain management at the company, said the firm’s revenues are “well north of $100 million.” But whereas a traditional retailer might have few large selling seasons that last from one to three months – at FabFitFun they are shipping million’s of boxes per year, with 11 pickable items per box to which members often add an additional 2 to 3 items. And the goods all ship within five to fifteen days depending on the sale event. “We have the same volume during seasonal peaks as Amazon’s largest West Coast facility.” Mr. Van Erlach explained.

To support these surges, the direct-to-consumer retailer built a 600,000-square-foot warehouse in Chino, California, in 2018. The warehouse operates using advanced software: a warehouse management system from Körber Supply Chain Software, a warehouse execution system from Bastian Solutions, and cartonization and shipping software from EasyPost.

Because the other solutions must integrate to the WMS, the WMS is, perhaps, the key piece of software. A warehouse management system supports warehouse processes such as receiving, put-away, picking, value added services (VAS), and shipping. To do this the system must manage fulfillment orders, warehouse tasks, inventory locations, the status of work, and resources that include both humans and machines.

Why did this subscription retailer select Körber? There were a few reasons. One is that the solution scales. Mark Gavin, the senior director of global IT at FabFitFun, said the solution can handle millions of orders dropped into the WMS all at once that then get processed over a few hours. Körber was able to ingest orders in hours while “the competitors were quoting days.”

Secondly, the Körber solution was very flexible. The system let them conduct business the way they wanted to, Mr. Gavin said. Körber allowed them to mold the “software around our business instead of the other way around.”

Körber was also able to develop a piece of custom code to support a complex kitting process. When products are packed into a box to support a customer’s order, those customers have choices. Customers are asked, “do you want this product or do you want to substitute one of these other products?” It is not the same items going into every box. If there were just a few options, a few different bills of materials could be created that direct packers which box to select and which items go in that box. But because of the plethora of choices, there were actually over 35 million possible kitting configurations this season, the bill of material methodology was just not feasible. FabFitFun and Körber developed special functionality that allowed the retailer to handle all the kitting complexity.

With their WMS, they have visibility of the flow of work between and across assets. Their waving strategy assigns orders to the available assets, allowing them to increase output by creating a very smooth flow of work across the entire building. Otherwise, a work area could become “overwhelmed,” work areas dependent on that asset would end up waiting for work, and the output from the building would end up getting “choked.”

Mr. Van Erlach is also high on their cartonization and shipping software from EasyPost. The cartonization software, based on the dimensions and shape of the products going into a carton, shows workers just how the products need to be packed and ensures the products ship in the smallest possible carton. The MagicLogic solution “plays Tetris with all the items in the order, “Mr. Van Erlach explains. The result is FabFitFun can fit more items on a truck, save trees and lower costs.

The shipping software rate shops for carrier costs, which depend on the destination, dimensions and weight of the box. “Before we even make the box, we rate shop it across a number of different last-mile carriers against our contracts, and it’s against every node of that carrier,” Mr. Van Erlach explained. “So, let’s say FedEx may have five locations, and each one of them is returning a quote for the box. We pick the one that we want to use systemically. All that happens in fractions of a second.” The solution also allows for zone skipping, which can also save significant amounts of money. Zone skipping is the practice of delivering a large quantity of packages via truckload or less-than-truckload to a parcel carrier hub close to the package’s final destination. Zone-skipping makes for quicker delivery to customers and allows us to keep prices to members lower than otherwise.

The Chino warehouse employs 200 full-time employees. However, to handle the box event surges, it will hire up to 800 temps. Mr. Van Erlach said, “we’re known for our ability to ramp on a dime.” The distribution center can go from ship shipping out thousands of orders to two shifts later being able to ship out a hundred thousand plus orders in a day.

That is a surprisingly large employment ramp, but Mr. Erlach says they don’t really have problems getting the temp workers. “We pay very competitive wages. We give prizes during the seasons. We’re a fun place to work. The warehouse is very, very clean. It’s a very, very safe environment.”

Finally, picking orders can be exhausting in a manual warehouse. But this is a goods-to-person warehouse. In other words, workers are not pushing a cart over 10 miles a day. They are at a station, and the goods come to a pick-to-light station, where a light comes on, and a worker picks the product behind the lit-up slot and then puts it in a carton. The pick-to-light solution and the software that runs those stations come from Bastian Solutions.

All the hardware and software solutions were implemented and integrated in just nine months. That is very fast for a warehouse with this degree of complexity.

FabFitFun has had great results from this combination of solutions. “Our labor cost went up by 50% during COVID. But our cost per order dropped by two-thirds,” Mr Van Erlach enthused. In other words, their costs were dropping by more than 66% while their labor costs increased 50%. And their cartonization and shipping led to significant savings in transportation. “This all adds up to tens of millions a year in savings.”

Finally, the warehouse is not just a cost center, it is also a profit center. The company is not just a retailer, they are also a third-party logistics provider. Their capabilities in warehousing and shipping have led several other retailers to pay them to fulfill orders for them.

The post The Retailer FabFitFun Excels at Logistics appeared first on Logistics Viewpoints.

Continue Reading
Click to comment

You must be logged in to post a comment Login

Leave a Reply

Non classé

What a Return to the Red Sea Could Mean for the Container Market

Published

on

By

What a Return to the Red Sea Could Mean for the Container Market

November 26, 2025

Blog

As the fragile but still-in-place Israel-Hamas ceasefire nears the two-month mark, and with the Houthis declaring an end to attacks on passing vessels, there is more and more anticipation that the long-awaited return of container traffic to the Red Sea may be coming soon.

Though Maersk maintains it has not set a date, the Suez Canal Authority stated that Maersk will resume transits in early December. ZIM’s CEO recently stated that a return in the near future is increasingly likely, and CMA CGM is reportedly preparing for a full return in December.

Operational Impact

The shift of most of the 30% of global container volumes that normally transit the Suez Canal away from the Red Sea and around the Cape of Good Hope almost exactly two years ago added seven to ten days and thousands of nautical miles to Asia – Europe journeys and to some Asia – N. America sailings as well.

The return of container traffic to the shorter Suez route will result in the sudden early arrival of these ships, which will mean significant vessel bunching and congestion at already persistently congested European hubs. This congestion will cause delays and absorb capacity which could push container rates up on the affected lanes, and possibly beyond.

The shift back through the Suez Canal may initially keep some of the typically lower volume ports in Europe that have become transhipment centers during the Red Sea crisis, like Barcelona, busy while carriers may omit port calls at some of the congested major hubs. But after the unwind, these ports, as well as African ports that have been used as refuelling stops during the last two years, will see port calls decline.

Carriers have plans for a gradual phase in of the transition back to the Red Sea, with smaller vessels starting to transit first. This approach would still cause vessel bunching, but would be aimed at minimizing the impact of the reset as much as possible.

But some carriers are skeptical that an orderly phase-in will happen, as they expect pressure from customers who will want a return to the shorter route as quickly as possible. Analysis from Sea Intelligence suggests that the more gradual the transition, the less disruptive it will be, while the faster the return the more disruptive it will be during the up to two months it will take for schedules to return to normal.

Ocean expert Lars Jensen also notes that a return during the lead up to Lunar New Year would coincide with an increase in demand, and would put more pressure on ports and rates than if the transition takes place post-LNY when demand is typically weak. With carriers signalling the shift will begin in December and pre-LNY demand probably picking up in mid-January next year, it seems likely the two will coincide.

Implications for Capacity – and Rates

Red Sea diversions were estimated to have absorbed about 9% of global container capacity by keeping ships at sea for longer and – with longer journeys meaning vessels would arrive back at origins days behind schedule – via carriers adding extra vessels to services in order to maintain planned weekly departures.

This drain on capacity caused Asia – Europe rates to more than triple and transpacific rates to more than double in the two months from the time the diversions began to just before Lunar New Year of 2024. And though rates moved up and down along with seasonal changes in demand, the capacity drain pushed East-West rates up to 2024 highs of $8,000 – $10,000/FEU and set a highly elevated floor of $3,000 – $5,000/FEU during low demand periods that year.

But even with Red Sea diversions continuing to absorb capacity in 2025, continued fleet growth through newly built vessels entering the market has meant that the container trade has already become significantly oversupplied.

As such, rates on these lanes – even before the capacity absorbed by diversions has re-entered the market – have consistently been significantly lower than in 2024 even during months when volumes have been stronger, with prices on some lanes reaching 2023 levels for a span in early October. Recent carrier struggles maintaining transpacific GRIs point to this challenge already.

Even with Red Sea diversions continuing and even during months in 2025 with stronger year on year volumes, capacity growth has meant rates in 2025 have been lower than in 2024.

Yes, the initial congestion and delays caused by the transition back to the Suez Canal will at first put upward pressure on rates for Asia-Europe containers and probably to a lesser degree on the transatlantic lanes as well. If the congestion ties up enough capacity or impacts operations at Far East origins, the rate impact could spread to the transpacific as well. As noted above, if the return coincides with the lead-up to LNY, it will have a stronger impact on rates as there will be pressure from the demand side as well.

But once the congestion unwinds and container flows and schedules stabilize the shift will ultimately release more than two million TEU of container capacity back into the market. This surge will put even more downward pressure on rates and increase the challenge of effectively managing capacity for carriers seeking to keep vessels full and rates profitable in 2026.

Judah Levine

Head of Research, Freightos Group

Judah is an experienced market research manager, using data-driven analytics to deliver market-based insights. Judah produces the Freightos Group’s FBX Weekly Freight Update and other research on what’s happening in the industry from shipper behaviors to the latest in logistics technology and digitization.

Put the Data in Data-Backed Decision Making

Freightos Terminal helps tens of thousands of freight pros stay informed across all their ports and lanes

The post What a Return to the Red Sea Could Mean for the Container Market appeared first on Freightos.

Continue Reading

Non classé

Transpac ocean rates fizzle; Red Sea return coming soon? – November 25, 2025 Update

Published

on

By

Transpac ocean rates fizzle; Red Sea return coming soon? – November 25, 2025 Update

Discover Freightos Enterprise

November 25, 2025

Blog

Weekly highlights

Ocean rates – Freightos Baltic Index

Asia-US West Coast prices (FBX01 Weekly) decreased 32% to $1,903/FEU.

Asia-US East Coast prices (FBX03 Weekly) decreased 8% to $3,443/FEU.

Asia-N. Europe prices (FBX11 Weekly) decreased 1% to $2,457/FEU.

Asia-Mediterranean prices (FBX13 Weekly) increased 6% to $2,998/FEU.

Air rates – Freightos Air index

China – N. America weekly prices decreased 2% to $6.50/kg.

China – N. Europe weekly prices decreased 1% to $3.97/kg.

N. Europe – N. America weekly prices increased 1% to $2.33/kg.

Analysis

Despite higher tariffs since early this year, US retail sales have proved resilient and are expected to grow through the holiday season. The solidifying tariff landscape is nonetheless facing destabilizing forces like recent China-Japan tensions, and the US Supreme Court’s pending decision on the legality of Trump’s IEEPA-based tariffs.

But the White House is signalling it is already taking steps to ensure that a SCOTUS loss will not open a low tariff window. So, if consumer spending remains strong, and the status quo of the trade war holds up, the US could enter a restocking cycle in 2026 as frontloaded inventories wind down. This restocking could mean stronger freight demand than some have anticipated for next year.

On the freight supply side though, there is more and more discussion of container traffic’s coming return to the Red Sea as the fragile Israel-Hamas ceasefire remains in effect. And while most carriers are not offering a timeline, ZIM’s CEO recently stated that a return in the near future is increasingly likely.

The shift of most of the 30% of global container volumes that normally transit the Suez Canal away from the Red Sea and around the Cape of Good Hope almost exactly two years ago added seven to ten days and thousands of miles to Asia – Europe journeys and to some Asia – N. America sailings as well.

The return of container traffic to the shorter Suez route will result in the sudden early arrival of these ships, which will mean significant vessel bunching and congestion at already persistently congested European hubs. This congestion will cause delays and absorb capacity which could push container rates up on the affected lanes, and possibly beyond.

Carriers have plans for a gradual phase in of the transition back to the Red Sea, with smaller vessels starting to transit first. This approach would still cause vessel bunching, but would be aimed at minimizing the impact of the reset as much as possible.

But some carriers are skeptical that an orderly phase-in will happen, as they expect pressure from customers who will want a return to the shorter route as quickly as possible. Analysis from Sea Intelligence suggests that the more gradual the transition, the less disruptive it will be, while the faster it is the more disruptive it will be, and the more pressure it will put on freight rates during the up to two months it will take for schedules to return to normal.

Ocean expert Lars Jensen also notes that a return during the lead up to Lunar New Year would coincide with an increase in demand, and would put more pressure on ports and rates than if the transition takes place post-LNY when demand is typically weak.

The capacity absorbed through Red Sea diversions pushed East-West rates up to highs of $8,000 – $10,000/FEU in 2024 and set a highly elevated floor of $3,000 – $5,000/FEU during low demand periods that year. But even with Red Sea diversions still in place this year, rates on these lanes have consistently been significantly lower than last year, with prices on some lanes reaching 2023 levels for a span in early October.

The transition back to the Suez Canal – be it more or less chaotic – will ultimately release more than two million TEU of container capacity back into the market. This surge will put even more downward pressure on rates and increase the challenge of effectively managing capacity for carriers seeking to keep vessels full and rates profitable.

The current overcapacity on the East-West lanes is the main reason that carriers’ November transpacific GRIs which had pushed West Coast rates up by $1,000/FEU this month to about $3,000/FEU have now fizzled.

Asia – N. America West Coast prices fell 32% last week to $1,900/FEU with daily rates this week down another $100 so far, but prices remain above the $1,400/FEU low for the year hit in early October. Last week’s vessel fire at the Port of LA does not seem to have had an impact on prices as operations have quickly recovered. Rates to the East Coast fell 8% to $3,400/FEU last week but are at $3,000/FEU so far this week, about even with levels in early October before these set of GRI introductions.

Meanwhile, October and November’s GRIs on Asia-Europe lanes have stuck, with rates to Europe and the Mediterranean both 40% higher than in early October at $2,500/FEU and $3,000/FEU respectively. These rate gains may be surviving on aggressive blanked sailings on these lanes.

Carriers are planning additional GRIs for December aiming for the $3k-$4k/FEU level as they continue to reduce capacity – with an announced labor strike in Belgium likely to help absorb some supply – but there are signs that these increases may not take.

In air cargo, peak season demand is driving rates up and should keep doing so for the next couple weeks. Freightos Air Index data show ex-China rates remaining strong at about $6.50/kg to N. America and $4.00/kg to Europe last week. Demand out of S. East Asia has grown significantly during this year’s trade war, with rates also elevated on these lanes at $5.40/kg to the US and $3.50/kg to Europe.

Discover Freightos Enterprise

Freightos Terminal: Real-time pricing dashboards to benchmark rates and track market trends.

Procure: Streamlined procurement and cost savings with digital rate management and automated workflows.

Rate, Book, & Manage: Real-time rate comparison, instant booking, and easy tracking at every shipment stage.

Judah Levine

Head of Research, Freightos Group

Judah is an experienced market research manager, using data-driven analytics to deliver market-based insights. Judah produces the Freightos Group’s FBX Weekly Freight Update and other research on what’s happening in the industry from shipper behaviors to the latest in logistics technology and digitization.

Put the Data in Data-Backed Decision Making

Freightos Terminal helps tens of thousands of freight pros stay informed across all their ports and lanes

The post Transpac ocean rates fizzle; Red Sea return coming soon? – November 25, 2025 Update appeared first on Freightos.

Continue Reading

Non classé

How AI Is Driving the Future of Industrial Operations and the Supply Chain

Published

on

By

How Ai Is Driving The Future Of Industrial Operations And The Supply Chain

ARC Industry Leadership Forum • Orlando, Florida
February 9–12, 2026 • Renaissance Orlando at SeaWorld

Artificial intelligence is reshaping how industrial organizations run their operations and supply chains. The shift is real. The early experiments are gone. Today, companies are redesigning their planning, logistics, reliability, sourcing, and production workflows around systems that can think, react, and coordinate.

At ARC Advisory Group, we’re seeing this change accelerate every quarter. AI is moving from a standalone project to the connective tissue between operational systems. It’s improving how energy is consumed, how materials flow, how assets behave, and how teams respond to uncertainty.

This February, leaders from across the world will gather in Orlando to break down where AI is creating value and what comes next.

Event Details
Renaissance Orlando at SeaWorld
6677 Sea Harbor Drive, Orlando, FL 32821
February 9–12, 2026
Event link: https://www.arcweb.com/events/arc-industry-leadership-forum-orlando

More than 200 colleagues are already registered, including Conrad Hanf and a broad mix of executives, operations leaders, and technologists.

Why AI Matters Right Now

AI gives industrial organizations three capabilities they’ve never had before.

Real-time awareness.
Factories, yards, pipelines, fleets, and distribution nodes are producing enormous amounts of data. AI helps cut through that noise. It identifies what matters, when it matters, and why. The result is faster decisions and fewer surprises.

Coordination across functions.
Production affects logistics. Maintenance affects throughput. Sourcing affects lead time. AI lets these domains share context and act together instead of waiting for a meeting or a spreadsheet adjustment. Decisions that once took a day now happen instantly.

Pattern recognition at scale.
AI sees the earliest signals of asset degradation, demand shifts, port delays, or supply risk. It doesn’t wait for a problem to become a crisis. It alerts teams early and recommends actions with enough lead time to matter.

What Leaders Are Focusing On

Across our research and briefings, the same themes keep rising to the surface.

AI-driven maintenance and reliability.
Predictive models are becoming the default. They diagnose root causes, calculate the impact of failure, and help schedule work when it makes operational sense.

Modern planning and scheduling.
Forecasts now incorporate external signals, real-time plant conditions, and multi-site interactions. Planners are starting to work with continuously updated recommendations instead of static plans.

Autonomous supply chain operations.
AI agents are beginning to negotiate with carriers, re-route shipments, rebalance inventory, and adjust sourcing strategies. This isn’t sci-fi. It’s quietly happening in live networks.

Graph intelligence.
Industrial networks are connected by thousands of relationships. Knowledge-graph models help organizations understand those connections and trace how one event cascades across an entire operation.

Data discipline.
AI’s performance depends on clean, harmonized data across ERP, MES, historians, WMS, TMS, and supplier systems. Many companies are now tackling this foundational work head-on.

Human and AI collaboration.
The most successful organizations aren’t automating people out. They’re giving operators, planners, and engineers AI tools that amplify experience and judgment.

Why Attend the ARC Industry Leadership Forum

The Forum is where these shifts come together. Attendees will see:

• Real-world case studies from global manufacturers, logistics leaders, and utilities
• Demonstrations of AI-enabled control towers and reliability platforms
• Deep-dive sessions on agent-based systems, context management, RAG assistants, and graph reasoning
• Roundtable conversations with peers facing the same operational pressures
• Practical discussions on governance, cybersecurity, workforce roles, and measurable ROI

This event is built for leaders who want clarity, validation, and a realistic roadmap for scaling AI across the industrial value chain.

A Turning Point for Industrial Operations

AI is changing the fundamentals of how materials move, how assets perform, how demand is met, and how decisions get made. The organizations that learn to use this intelligence well will operate with more resilience, more predictability, and less friction.

The ARC Industry Leadership Forum is the best place to understand what this looks like in practice and how to prepare your organization for it.

Join Us in Orlando

If your role touches operations, supply chain, engineering, logistics, maintenance, or industrial strategy, this gathering will be well worth your time.

Reserve your seat:
https://www.arcweb.com/events/arc-industry-leadership-forum-orlando

We hope to see you there.

The post How AI Is Driving the Future of Industrial Operations and the Supply Chain appeared first on Logistics Viewpoints.

Continue Reading

Trending