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The Retailer FabFitFun Excels at Logistics

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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.

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The Freight Forwarder Moat Is Getting Shallower

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The Freight Forwarder Moat Is Getting Shallower

Ocean freight forwarding is an $80+ billion market bogged down by the manual processes related to booking management, documentation services, and the coordination labor that holds it all together.

When working with a freight forwarder, you’re buying three things bundled together:

Carrier relationships — access to capacity, negotiated rates, allocation commitments.
Operational data — knowing which carrier fits a given lane, what documents a particular trade corridor requires, how to handle an exception when a booking gets rejected.
Coordination labor — the booking itself, the documents per container (industry estimates range from 9 to 18 depending on the corridor), the re-keying of data across disconnected systems, the email chains chasing confirmations and clearances.

Shippers have always paid for the bundle because you couldn’t get one piece without the others, but that’s changing.

Where the bundle comes apart

Travel agents used to bundle airline relationships, destination expertise, and the labor of putting trips together into a single fee. Aggregator platforms unbundled the pieces, and the booking layer went first because that’s where the volume was. Ocean freight forwarding is in the same position. More than digitizing booking, though, AI is automating it.

The bulk of the volume and labor cost for freight forwarders is tied up in rate comparisons across dozens of carriers, document preparation and routing by trade lane and commodity classification, booking execution against pre-negotiated contracts, and exception triage on rejected bookings.

But this is all high-volume, rule-governed, multi-system coordination where speed and consistency matter more than creativity. Exactly the type of work that AI agents are well-equipped to handle.

Platforms can now ingest a rate agreement, parse surcharges and FAK provisions into a digital rate profile, compare carriers on cost, transit time, and schedule reliability, and execute a booking based on pre-defined parameters, without a human in the loop.

Automating the entire order lifecycle

Every dollar of margin exposure in ocean freight traces back to a decision made without complete information. That means that every action must be rooted in live network data across shipment flows, carrier performance, and insight from inventory and order systems. A platform with that intelligence can automate and accelerate the full workflow from detecting a supply shortfall, selecting a carrier, booking the container, managing the documents, tracking the shipment, and handling exceptions.

A shipper stitching together a rate tool from one vendor, a booking portal from another, a document system from a third, and a visibility feed from a fourth gets digitization. They get a slightly faster version of the same manual process. The full picture still lives in a person’s head, and the handoffs between systems still require human coordination.

While freight forwarders and other intermediaries are also investing in AI, they’re primarily automating their own coordination labor before someone else absorbs it. But they can’t replicate the data advantage of a platform that sits across the entire supply chain.

A forwarder automating its booking desk draws on its own transaction history. A point solution built specifically for ocean booking draws on booking data. A platform processing millions of supply chain events daily across orders, inventory, carrier performance, and live shipment status, has a different signal base entirely. Carrier selection informed by real-time schedule reliability, live network disruption, and your actual inventory positions is structurally more accurate than carrier selection informed by historical rate tables.

The shrinking intermediary layer

The moats around freight forwarders’ profit margins are eroding, and the lines between legacy endpoint solutions are blurring. High-complexity corridors and specialized commodities still need human expertise, but the bread-and-butter containerized freight that makes up the bulk of forwarder revenue is the volume where automated workflows shine.

Meanwhile, software providers will have a hard time selling dashboards and chatbots to specific teams compared to AI-native platforms offering a single operating system across all supply chain operations, and serving downstream stakeholders.

The question for forwarders is how long they can keep patching automation onto a fragmented architecture with a booking tool here, a document system there, people bridging the handoffs in between. And how much revenue sits in structured, repeatable work that a connected platform absorbs?

For shippers, the choice is whether to invest in a platform that automates the order-to-delivery and exception lifecycle, or keep paying others to hold the pieces together. The second option is a decision to fund the intermediary layer sitting between them and their own data.

The post The Freight Forwarder Moat Is Getting Shallower appeared first on Logistics Viewpoints.

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Supply Chain and Logistics News Week of May 7th 2026

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Supply Chain And Logistics News Week Of May 7th 2026

The logistics and supply chain landscape is undergoing a fundamental transformation as industries move from rigid, low-cost models toward strategies defined by agility and resilience. This week’s roundup explores how major players are navigating this shift, from Amazon’s bold move to offer its massive infrastructure as a standalone service to Ford’s strategic manufacturing reset in the EV sector. We also dive into the critical human element in modern cost engineering, the logistical reimagining of energy corridors due to geopolitical risks, and the new AI-driven tools closing the gap between inventory detection and real-time execution. Together, these developments highlight a common theme: the pursuit of flexibility and data-driven intelligence in an increasingly unpredictable global market.

Top Supply Chain Stories from this Week:

Modern Cost Engineering Evolution: Rewiring the Human Element for Supply Chain Resilience

In the latest shift for cost engineering, the focus is moving beyond purely digital tools to address the critical human element required for true supply chain resilience. As industrial organizations transition from traditional backward-looking estimates to modern “should-cost” methods powered by AI and digital twins, the real challenge lies in workforce transformation. Success in this new landscape requires a significant cultural shift, moving away from isolated departmental silos toward cross-functional collaboration. By reskilling traditional estimators to act as strategic consultants—capable of interpreting material science and operational constraints—companies can evolve from simple price negotiation to collaborative manufacturing improvements that ensure mutual profitability and long-term stability.

Hormuz Risk Is Redrawing the Supply Chain Geography of Energy

Geopolitical instability in the Strait of Hormuz is forcing a fundamental shift in energy logistics, moving the industry away from lowest-cost network design toward a risk-adjusted model. With the waterway handling roughly 20% of the world’s oil and liquefied natural gas, repeated disruptions have transformed infrastructure like pipelines, storage terminals, and deep-water ports outside the Persian Gulf into high-value strategic assets. Nations and corporations are no longer viewing these as simple logistics nodes, but as essential escape routes that provide the optionality and recovery time needed to withstand chokepoint failures. This selective redesign of the global energy map signals a new era where geography and physical redundancy are the primary drivers of supply chain resilience.

Ford’s Manufacturing Reset Shows How Automakers Are Rebuilding the EV Supply Chain

Ford’s manufacturing pivot represents a fundamental shift from aggressive electric vehicle expansion toward capital discipline and supply chain flexibility. By taking a $19.5 billion write-down and restructuring battery joint ventures, the company is moving away from rigid, single-purpose production lines in favor of multi-energy platforms that can adapt to fluctuating demand for hybrids and EVs. A key component of this reset is the repurposing of battery manufacturing assets in Kentucky and Michigan for stationary energy storage and data center support. This strategy transforms these facilities into flexible energy infrastructure rather than just automotive supply nodes. Ultimately, Ford is signaling that the next phase of the market will be defined by the ability to manage uncertainty through cross-functional asset utilization and a focus on manufacturing-driven affordability.

How FourKites Connects Stockout Detection to Freight Execution in Minutes

FourKites has launched a unified solution that bridges the gap between stockout detection and freight execution, reducing resolution time from hours to less than five minutes. By integrating its Inventory Twin and Booking Connect AI, the platform eliminates the traditional “manual scavenger hunt” where planners had to jump between ERPs and carrier portals to resolve inventory gaps. The system uses decision intelligence to identify stockout risks up to six weeks in advance and provides ranked recommendations for corrective transfers based on cost, speed, and carrier performance. This closed-loop workflow allows planners to execute optimized shipping options with a single click, addressing the massive financial impact of inventory distortion and reducing the need for expensive, unplanned expedited shipping.

Amazon Launches “Supply Chain Services” Leveraging its Global Logistics Network

Amazon has officially launched Amazon Supply Chain Services (ASCS), a move that decouples its massive logistics infrastructure from its retail marketplace to serve as a standalone utility for all businesses. Similar to the trajectory of Amazon Web Services (AWS), the platform opens up Amazon’s multimodal freight, automated warehousing, and last-mile parcel delivery networks to companies regardless of whether they sell on Amazon. Major early adopters like Procter & Gamble, 3M, and Lands’ End are already leveraging the service to move everything from raw materials to finished products. By consolidating fragmented logistics contracts into a single automated interface, Amazon aims to use its scale—currently moving 13 billion items annually—to provide businesses with end-to-end visibility and 96.4% on-time delivery rates, signaling a significant new challenge to traditional 3PLs and carriers like FedEx and UPS.

Song of the week:

The post Supply Chain and Logistics News Week of May 7th 2026 appeared first on Logistics Viewpoints.

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How FourKites Connects Stockout Detection to Freight Execution in Minutes

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How Fourkites Connects Stockout Detection To Freight Execution In Minutes

FourKites is bridging the gap between identifying a problem and solving it. With the integration of Inventory Twin and Booking Connect AI. Traditionally, supply chain planners have been stuck in a manual scavenger hunt whenever a stockout alert surfaced, jumping between ERPs to find surplus stock and carrier portals to secure freight. This fragmented process typically took hours, often forcing companies to rely on expensive, last-minute expedited shipping or facing steep On-Time In-Full (OTIF) penalties to avoid customer dissatisfaction. By unifying these disparate data streams, the new solution allows teams to detect risks two to six weeks in advance and execute corrective transfers from a single, seamless workflow.

The impact on operational efficiency is significant, reducing the resolution time from detection to execution from several hours to less than five minutes. Instead of just receiving a warning, planners are presented with recommendations powered by Decision Intelligence that include the fastest, cheapest, and most optimal shipping options based on real-time carrier performance data. This closed-loop system directly addresses the 1.73 trillion dollar global issue of inventory distortion and aims to eliminate the 15-25 hours planners previously spent on manual coordination.

By keeping a human in the loop to select the best recommendation with a single click, FourKites ensures that exceptions are resolved without ever leaving the platform. This integration helps protect freight budgets, where unplanned expedited shipping often consumes up to 48% of total spend. This launch represents a shift from reactive firefighting to proactive execution, allowing teams to move away from costly safety stock and focus on high-value responsibilities. Supply chain planner responsibilities are changing with the continued developments of AI and the de-siloing of disparate systems.

FourKites is a supply chain technology provider that operates a global real-time visibility network tracking over 3.2 million shipments daily across 200 countries and territories. By integrating data from 1.1 million carriers across all modes (road, rail, ocean, and air), the platform uses AI-powered “digital workers” to automate exception resolution and provide predictive insights. More than 1,600 global brands, including leaders in the CPG and Food & Beverage sectors, trust FourKites to transform their logistics from reactive tracking into proactive, intelligent orchestration.

Read the full ARC brief breaking down the new FourKites solution here: https://www.fourkites.com/research/arc-advisory-stockout-detection-freight-execution/

The post How FourKites Connects Stockout Detection to Freight Execution in Minutes appeared first on Logistics Viewpoints.

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