Chapter 12 – The OM Blog by Heizer, Render, & Munson

OM in the News: AI Moves Into Physical Operations — Transforming Inventory, Quality, and Maintenance

AI is rapidly shifting from digital decision‑support to hands‑on operational control. As AI systems move into the physical world, they are reshaping core OM functions—especially inventory management, quality assurance, and maintenance. For operations managers, this marks a transition from AI as an analytical tool to AI as an active operational partner, writes The Orlando Sentinel (Sept. 20, 2026).

AI and Inventory Management Inventory systems (see Chapter 12 in your Heizer/Render/Munson text) are becoming increasingly autonomous. Instead of relying on periodic counts or manual updates, AI‑enabled sensors and vision systems now track materials in real time—monitoring stock levels, identifying misplacements, and even predicting shortages before they occur. Machine‑learning models can dynamically adjust reorder points, safety stock, and lot sizes based on demand variability, supplier reliability, and production schedules. The result is tighter control, lower carrying costs, and fewer stockouts.

AI‑Driven Quality Assurance Quality management (see Chapter 6) is undergoing a similar transformation. High‑resolution cameras, acoustic sensors, and thermal imaging feed continuous data streams into AI models capable of detecting defects far earlier—and more accurately—than human inspectors. Instead of sampling, AI enables 100% inspection at full production speed. These systems not only flag defects but also trace root causes by linking anomalies to machine settings, operator actions, or upstream materials. Quality becomes proactive rather than reactive.

Predictive and Autonomous Maintenance Maintenance (the topic of chapter 17) is perhaps the area where AI’s physical presence is most visible. Predictive maintenance models analyze vibration, temperature, and performance data to forecast failures before they occur. More advanced systems automatically adjust machine parameters to prevent breakdowns, optimize lubrication cycles, or balance loads across equipment. This reduces downtime, extends asset life, and stabilizes capacity planning.

The OM Challenge Ahead As AI becomes embedded in physical operations, managers must rethink process design, workforce skills, and risk management. Inventory, quality, and maintenance systems will increasingly operate autonomously—but they still require human oversight, ethical safeguards, and strategic alignment. The future OM leader must be fluent in both operational fundamentals and AI‑driven decision‑making.

Classroom Discussion Questions:

How will AI‑enabled real‑time inventory, quality, and maintenance systems change traditional OM decision frameworks?
What new risks arise when AI autonomously adjusts physical processes, and how should managers design controls to mitigate them?

OM in the News: Agentic AI Revolutionizes the Factory

It’s 4 a.m. at a large automotive parts plant. The night-shift supervisor freezes as the dashboard flashes an alert: a critical spindle is vibrating out of tolerance. In the old world, he’d wait for maintenance to evaluate and decide. But today, an AI agent has already paused the line, checked service records and called the right technician—before he even takes a step toward the control room.

That’s the new reality for many manufacturers facing a stubborn obstacle: the ever-widening gap between data and decisive action. Now, a new class of digital entities is changing that equation. AI agents powered by decision intelligence are beginning to sense, reason and act across the manufacturing ecosystem, cutting decision latency from minutes to milliseconds.

Think of AI agents as the digital nervous system of a modern factory. They continuously sense what’s happening across machines, people and systems, then respond intelligently without losing context. Across the manufacturing stack, they’re quietly reshaping work for every role:

On the shop floor: Agents merge operations and information technology (IT) data to give operators real-time context. They can recommend optimal machine parameters, trigger tool-change schedules, balance workloads across lines or alert technicians before deviations escalate. Maintenance teams can use agents to predict component wear and plan interventions that don’t interrupt production– a topic in Chapter 17.

In production and quality operations: Agents help supervisors and quality staff detect process drift early. They analyze sensor data, images and process variables, suggesting immediate corrections or automated parameter tuning. In continuous manufacturing, this can mean fewer rejects and less rework, which we discuss in Chapter 6.

In ERP and planning: Agents connect production, procurement and finance systems. A planning agent (see Chapter 14) can run simulations of “what if” scenarios, what happens if a supplier shipment is delayed or if energy costs spike and recommend production adjustments.

Across the supply chain: Agents can constantly monitor inventory, supplier performance and logistics signals. When a potential shortage or delay is detected, they are able to trigger contingency workflows such as redistributing available stock, recommending alternate suppliers or rescheduling deliveries–see Chapters 11 and 12.

To sum it up: “Tomorrow’s factories won’t just inform — they’ll decide,” writes Industry Week (June 12, 2026).

Classroom discussion questions:

Summarize what AI agents can do in a factory setting.
How does agentic AI have the potential to change the manufacturing operation?

OM in the News: The GLP-1 Effect–How Weight-Loss Drugs are Disrupting Inventory Management

The explosive popularity of GLP-1 weight-loss medications like Ozempic and Zepbound is changing more than just waistlines—it is fundamentally disrupting retail supply chains. The Wall Street Journal (June 8, 2026) reports highlights a massive surge in apparel returns, with some retailers experiencing a 50% spike. As consumers rapidly shed pounds, they are ordering multiple sizes of the same garment and sending back the ones that no longer fit.

Jeans, bras and athleisure wear are often the first items replaced as people drop weight.

This phenomenon serves as a real-world case study in the hidden costs of holding inventory and the critical importance of inventory accuracy, topics central to Chapter 12 of your Heizer/Render/Munson text.

The Hidden Cost of Retailing Reverse Logistics. Inventory doesn’t just sit safely on a shelf; it incurs holding costs, including warehousing, labor, and depreciation. When a customer returns an item, those costs multiply. Returned clothing often arrives out of season, forcing retailers to liquidate it at a steep markdown. For a $1 billion retailer, a mere 5- 10% increase in returns can slash gross margins by $20 million.

Mismatched Supply and Demand. Further, GLP-1 users are shifting the entire demand curve. Returns are spiking heavily in medium, large, and extra-large sizes, while demand for smaller sizes is skyrocketing. We write in the text that “inventory exists to decouple various parts of the production and distribution process. However, when demand shifts this rapidly, traditional forecasting models break down, leading to severe stockouts in smaller sizes and costly overages in larger ones.

To combat this, brands like June Adel are dynamically altering their ordering cycles, shifting safety stock levels to favor smaller dimensions, and utilizing stricter ABC analysis to track high-risk, high-return items.

Ultimately, the GLP-1 boom proves that inventory management is never static. To survive, retailers must tighten their supply chains, leverage sharper data, and treat reverse logistics not as an afterthought, but as a core operational variable.

Classroom Discussion Questions

How can retailers use safety stock and reorder point (ROP) calculations to mitigate the unpredictability of rapid consumer weight loss and high return rates?
Considering the high costs associated with reverse logistics, should retailers implement stricter ordering limits or higher restocking fees to optimize their total inventory holding costs, even if it risks lowering customer satisfaction?

OM in the News: Starbucks Ditches AI Inventory System After Just 9 Months

Starbucks is saying goodbye to its artificial intelligence inventory management system about nine months after its debut, writes Supply Chain Dive (June 4, 2026) . The tool, which used computer vision to track some parts of the chain’s inventory, was announced in September (see Supply Chain Dive (Sept. 3, 2025)as a method to simplify inventory record-keeping and prevent stockouts.

At that time, Starbucks’ CTO wrote: “The tech is currently live across thousands of coffeehouses, and will be in use across the chain’s entire North American system by the end of September. At cafes using the AI systems inventory is now counted 8 times more frequently, giving us real-time visibility and enabling faster, more precise replenishment.”

Now, however, the coffee giant is ending its computer vision inventory counting system — which employees called “unreliable” — in favor of traditional stock-keeping methods.

Starbucks has “moved to a single, consistent process across all inventory counts. This approach supports accuracy and product availability in our coffeehouses,” wrote the company. “We will continue to invest in technology and refine our tools over time.”

Starbucks shared negative internal employee comments on the changes to its inventory system –such as these two: “Very grateful our thoughts about AI count were heard.” And “Thank you for trusting the partners over unreliable spatial recognition to handle these counts.”

“We’re going to have daily replenishment by the end of 2026,” said the CEO. “If we’re going to do the food program that we want to do, we gotta have that. Because if we’re going to put items on our menu, we gotta be in-stock with those items.” He added the chain previously struggled with stockouts, which left some consumers feeling as if they were rolling the dice on the availability of key menu items.

Classroom discussion questions:

Did AI fail in this case?
What are the strengths and weaknesses of vision systems?

OM in the News: Drones Gain Manufacturing Altitude

Drones, in the headlines every day from Russia, Iran and Hezbollah, are also real manufacturing tools that can add valuable context and support. “They provide clear value in activities that are traditionally labor-intensive, disruptive or difficult to perform safely,” writes Industry Week (May 7, 2026).

Drones are making inroads in manufacturing in these two areas:

Inventory tracking: Indoor drones equipped with barcode scanners and computer vision systems can perform inventory scans with minimal disruption. In large warehouses or storage areas, they can significantly reduce cycle-count time and increase count frequency. The real-time data can be integrated into corporate software platforms, reducing excess stock and decreasing production delays due to stockouts.

Inspection: Conventional industrial inspections often require scaffolding, rope access, shutdowns or travel. They expose workers to heights, to confined spaces or to environmental hazards. Drones can transform this activity. High-resolution visual, thermal, ultrasonic and lidar payloads allow inspection of hard-to-reach areas, including storage tanks and silos, pipe racks, roof structures and overhead utilities. For remote manufacturing facilities, a drone mission can eliminate days of logistics and increase safety performance.

The business impact is measurable: reduced downtime, lower mobilization costs, reduced safety risk and faster response to problem detection. In the energy and utilities sector, drone-based inspection has been estimated to reduce inspection costs by 70% and downtime by 90%.

Future innovation: The next stage in drone deployment is autonomous operation. Drones will increasingly operate from fixed docking stations, launching automatically to perform scheduled inspection missions. Data collected during these flights can be transmitted to AI-enabled analytics platforms and integrated into operational systems in near real-time. Coordinated drone swarms may be used to conduct large-scale inspections and surveys across a large infrastructure.

Challenges: Concerns about workforce displacement are common, and the increased adoption of drones is no exception. But drone programs typically augment skilled labor rather than replace it. Technicians can become certified drone pilots, remote inspection specialists, data analysts or AI-assisted defect reviewers.

Modern industrial drones are connected devices and must be treated as operational technology nodes within the broader cybersecurity architecture. A compromised drone platform presents a risk that goes beyond simple device failure. It may expose critical infrastructure data or provide a means to compromise enterprise networks.

Still, a fully scaled drone program that makes good use of its data is a significant strategic asset.

Classroom discussion questions:

What other industries are already commonly using drones?
Discuss their use in modern warfare.

OM in the News: The Inventory Return Scam

Retailers nationwide have seen online returns skyrocket over the past four years after rolling out generous returns policies to attract customers amid a pandemic-driven surge in e-commerce. The returns policies have helped change shopping habits: Consumers have grown accustomed to ordering items online in several sizes and colors, then returning what they don’t want.

Shoppers last year returned 17.6% of items they purchased online, valued at more than $247 billion and more than double the percentage of goods returned in 2019. Returns have become such an entrenched part of online commerce that companies have sprung up to handle the growing business. UPS acquired one of those specialized operators, Happy Returns, for $465 million.

The ease of shipping goods back has also given criminals new tools to exploit in an online environment in which buyers don’t need to interact with store employees–and the scale and organization of the fraud is getting more ambitious, and organized. More than $100 billion in merchandise was returned fraudulently in the U.S. last year, estimated to be 9-15% of the $850 million returned goods retailers received in 2024-2025, reports Supply Chain Brain (Feb. 2, 2026).

Organized criminal groups “are taking advantage of the omnichannel retail environment,” said on industry expert. In some cases, fraudsters are returning knockoffs in place of designer goods and sending back boxes full of bricks or other filler rather than the original items. Others are manipulating shipping labels to receive a refund just from mailing back an empty envelope. Fraudsters marketing their services on Telegram and through other websites often sell their services in return for a cut of customers’ refunds.

Apparel retailer PacSun recently noticed a sharp increase in returns of online purchases, including one customer who had returned some 250 orders worth $24,000. PacSun had issued the refunds, but the company never received the actual merchandise at its warehouse. Instead, workers found “used or different merchandise returned in the box, or even empty shoeboxes.”

Some retailers such as Amazon are taking legal action. It just sued the refunding-services group REKK that it claimed was “responsible for stealing millions of dollars of products from Amazon’s online stores through systematic refund abuse.”

Classroom discussion questions:

How can the quality control inspections engaged during returns processing be defrauded?
How has e-commerce made this fraud easier?

Guest Post: From No Frills to Trendy Food, Fashion and Home, Walmart’s New Product Assortment

Professor Misty Blessley, at Temple U., cohosts many of our podcasts, as well as sharing her insights with our readers monthly.

Value retailer, Walmart, known for focusing on price-sensitive shoppers, has moved into premium products and broader brand assortments, with the goal of winning over customers with more buying power. Appealing to higher-income customers (those earning over $100,000), requires the firm to shift from a no-frills mindset.

The firm remains committed to everyday-low-pricing (EDLP), thus it must continue managing this highly effective strategy while integrating broader lines. This requires a supply chain flexible enough to support both high-turn grocery and slower fashion and lifestyle products, for example.

On the inbound supply chain side, Walmart diversifies its supply base to procure new products. As is outlined in Chapter 11 of your Heizer/Render/Munson book, this requires identifying, vetting and selecting new suppliers as well as a host of supply-side tasks like vendor and contract management.

Managing inventory requires additional adaptations. Walmart refreshed the look of its website and stores while avoiding alienating its historical customers. It did so by keeping flagship items in stores and premium lines at distribution centers. Chapter 12 outlines inventory concerns Walmart faces, from the importance of inventory record accuracy to strategies for managing inventory.

On the outbound side, the firm’s e-commerce and fulfillment operations must be capable of satisfying wealthier customers, who often expect faster, higher-service delivery options, such as same-day delivery or premium curbside pickup. Meeting these expectations puts pressure on Walmart’s fulfillment network for more micro-fulfillment centers and localized inventory pools to reduce delivery times. Facility, inventory, and transportation cost trade-offs are also covered in Chapter 11.

Walmart is an exemplar in omnichannel retailing because it seamlessly integrates its physical stores, online platforms, supply chain, and last-mile services into a unified customer experience. Its customers purchase and receive products when, where and how desired. Walmart is offering frills next to its no-frills strategy.

Classroom Discussion Questions:

How would you call upon Ch. 11 and 12 as a Walmart supply chain manager?
Some firms target different customer segments under different brand names. For example, Gap Inc. owns Gap, Old Navy, Banana Republic and Athleta. Walmart has chosen a different strategy. How is Walmart capable of serving its price-sensitive and wealthier customers under one brand?

Guest Post: Omnichannel Operations–Where Technology Meets Retail Strategy

Dr. Prince Vijai is Assistant Professor of Operations at IBS Hyderabad, India. This post is based on his recent presentation at the DSI meeting in Orlando.

In today’s retail world, customers expect a smooth and unified experience across both online and offline channels. This customer expectation has turned omnichannel inventory management into a strategic necessity. By integrating supply chain management, information systems, and analytics, retailers can ensure that products are available where and when customers need them – across stores, warehouses, and digital channels.

Centralized inventory visibility is the key enabler of this unified commerce inventory strategy. Instead of managing separate stock pools, leading retailers maintain a unified view of inventory across all sales channels. This reduces overstocking, prevents stockouts, and supports flexible fulfillment options, such as ship-from-store, click-and-collect, buy online pickup in-store (BOPSIS), and dropshipping.

To achieve this omni-channel inventory visibility, real-time data synchronization is essential. Technologies like Shopify APIs and AWS Lambda update stock levels instantly as purchases occur, ensuring accuracy across systems. NoSQL databases, such as DynamoDB or Firebase, provide the scalability and speed necessary for these continuous updates.

Leading retailers clearly demonstrate the benefits of such integrated omnichannel operations. Zara uses RFID for item-level tracking, enabling rapid replenishment and online fulfillment from its stores. Nike uses a unified commerce platform to synchronize data across its physical and digital channels. Amazon exemplifies data-driven order routing and fulfillment efficiency.

As omnichannel operations mature, the role of the Omnichannel Planner is emerging. This is a professional skilled in analytics, ERP, and API integration who aligns supply with demand across channels. Such expertise ensures a balance between operational efficiency and superior customer experience.

The key omnichannel retail trends include unified commerce integration, adoption of practical generative AI, enhanced inventory visibility, flexible fulfillment options, and personalized in-store experiences. These strategies aim to strike a balance between customer value and operational efficiency, driving agility and competitiveness.

Ultimately, omnichannel inventory management represents more than just logistical coordination – it’s a foundation for business agility and customer satisfaction. Retailers mastering this capability gain a decisive edge in speed, accuracy, and trust in a competitive, data-driven marketplace.

Classroom Discussion Questions

1.How does real-time data synchronization enhance both customer experience and retailer performance?

2. What future technologies could further improve omnichannel inventory visibility?

Guest Post: Forecasting, Inventory Management, and “No-Buy 2025”

Professor Misty Blessley at Temple U. looks at the “No- Buy” movement.

Thanksgiving is just 3 months away, and Christmas only 4, but the holidays are long upon retail supply chains. At the same time, a growing number of consumers are pushing back against the pressure to spend, embracing a movement known as “No-Buy 2025,” which is gaining serious traction.

At its core the movement is a consumer mindset focused on refraining from non-essential purchases for a set period, for some an entire year. Trending on online communities are people sharing their No-Buy challenges and success stories. Some are motivated to cut debt or save for long-term goals, while others are concerned with sustainability, minimalism, or anti- consumption values. Participation is surging, especially among millennials and Gen Zs, who are juggling inflation, student debt, and climate anxiety.

Baby boomers, in contrast, are known to possess a large portion of total disposable income and to spend on luxury and leisure items. Participants are cutting back on categories often linked to impulse spending or excess and are instead using what they have:
 Apparel and accessories
 Home décor and seasonal items
 Beauty and skincare
 Toys and impulse gifts
 Functioning electronics

Why It Matters for Supply Chains
No-Buy 2025 has a ripple effect on retail supply chains. The holiday season typically drives massive retail volume, but with intentional non-buying, companies could face missed orders if underestimating demand or excess inventory if forecasts are too high.

Many demand forecasts rely on past trends, but for some generational cohorts demand is eliminated or potentially delayed. Retailers may need to reconsider their demand planning models, where inventory is held in the network, and be aware of consumer behavior (e.g., generational preferences, while remembering that generalizations are, by nature, generalizations). Supply chains that account for today’s values will be best positioned to respond.

Classroom discussion questions:
1. What are the shortcomings with traditional time-series and seasonality forecasting methodologies given the no-buy movement?

2. Do you think the product categories identified above should be forecasted differently when compared to one another? Why?

3. How does the purchasing power of various generational cohorts come into play?

Note: The Silent Generation (born 1928-1945), Baby Boomers (born 1946-1964), Generation X (born 1965-1980), Millennials (born 1981-1996), Generation Z (born 1997-2012), and Generation Alpha (born 2013-2024).

OM in the News: Self-Checkout Era May Be Ending As Major Retailers Shut It Down

For over a decade, self-checkout was the retail future, speed, convenience, and cost savings. However nine of the largest retailers in the world are kicking these systems to the curb in an unbelievable reversal, reports MSM.com (June 30, 2025).

The numbers are brutal. Theft at self-checkout can be up to 65% higher than at regular lanes, with shrinkage hitting 3.5% of sales compared to just 0.21% with human cashiers. One study found 15% of users admit to stealing at kiosks, and 44% say they’d do it again. That adds up to over $10 billion in losses for food retailers each year. It’s not just career criminals. With no one watching, people blur the lines, blaming tech errors or telling themselves it doesn’t hurt anyone. With self-checkout transactions 16 times more likely to involve theft, stores are realizing the convenience comes at a staggering cost

As retailers like Dollar General and Walmart scale back self-checkout, the industry seeks a new approach balancing efficiency with personalized service. Self-checkout may save on payroll, but it comes with theft, tech breakdowns, customer frustration, and weakened brand loyalty.

Dollar General has taken one of the boldest steps away from self-checkout. Last year, the chain yanked self-checkout from 12,000 of its 20,000+ stores, dropping its earlier push toward 100% self-service locations. Its CEO blamed “shrink,” or inventory loss, calling self-checkout the company’s biggest obstacle. Remaining kiosks now cap purchases at five items.

Five Below quietly pulled self-checkout from its highest-risk stores, revealing a tough truth, automation doesn’t work everywhere. Returning to staffed lanes did more to curb theft than adding extra security. The data showed that some neighborhoods saw massive spikes in shoplifting when kiosks went unmanned. So the company tailored its checkout systems based on local risk.

Walmart is testing a new tactic: limiting self-checkout access to Walmart+ members in select stores. It’s a bold shift that makes automation feel more like a premium perk than a standard option. The move helps reduce theft by tying kiosk use to verified customer accounts.

Amazon’s grand vision for cashierless shopping hit a wall last year when it dropped “Just Walk Out” from its Fresh grocery stores. The tech, which was supposed to track purchases automatically, relied heavily on human reviewers, over 1,000 people in India checking transactions manually. Some 70% of purchases needing intervention.

Classroom discussion questions:

Do you think self-checkout is going to fade away?
What technology is needed to improve the system of self-checkout?

Guest Post: Fashion Influencers and Revamping Costly Product Returns

Temple U. Professor Misty Blessley raises an interesting inventory issue–returns.

Fashion influencers and their followers are contributing to the increase in rising product returns. According to the National Retail Federation, returns accounted for 17% of retailers’ total 2024 sales. Online purchases have a 26% return rate compared to in-store purchases (10%). Many online shoppers intentionally buy items they plan to return. Statista reports that clothing (24%), shoes (16%), and accessories (12%) are the most returned products – the exact product footprint of fashion retailers. Several recent articles shed light on the influencer effect and tips for revamping costly product returns in retail fashion.

Fashion influencers have popularized trends that promote returns behavior:

Hauls: Influencers showcase purchased fashion items, then decide whether to keep or return them based on follower feedback.
Wardrobing: Influencers buy items for temporary use such as content creation and return them afterward.
Bracketing: Influencers buy multiple sizes or colors of a product to find the perfect fit, with the intention of returning the rest. About 58% of consumers buy multiple sizes for this reason, with 75% of returns attributed to fit.
Influencing: 56% of followers make purchases recommended by an influencer, many of which are later returned.

Returns come with significant costs, including shipping, restocking, reselling at a discount, and administrative expenses. Retailers are adopting strategies to curb or better manage returns:

Charging return fees: Brands like Zara and H&M now charge for returns.
Clarifying return policies: Shortened return windows, stricter conditions for full refunds, and more items marked as final serve to narrow return opportunities.
Improving sizing tools: Enhanced size charts, virtual reality fitting tools, and online fitting rooms help shoppers make better choices.
Implementing logistics systems: Retailers are investing in digital tools to streamline and manage returns more efficiently.

As discussed in Chapter 1 of your Heizer/Render/Munson textbook, best practice can be achieved when operations and supply chain management, marketing, and finance work together.

Classroom discussion questions:

After 89% of retailers adjusted their policies to deter returns, 59% saw return rates increase. What factors could explain why these policies fail to get the desired result?
The SCOR Model, discussed in Chapter 11, outlines attributes for processes like source, make, and deliver. How are the attributes for returns like or different from these processes?

OM Podcast #20: Manufacturing and Operations at Nautique Boats

In our latest podcast Barry speaks with VP of Operations at Nautique, Kris Hanigosky, about operations for this luxury ski boat manufacturer (known for its iconic Ski Nautique). They discuss maintaining the highest levels of quality, the importance of accuracy in forecasting and inventory management, and innovative approaches to employee retention through upskilling.

Heizer Render OM Podcast · OM Podcast Episode #20 (5/27/24): Manufacturing & Operations at Nautique

Did you know our podcast is now available on Apple podcasts? Just go to your Apple podcasts app, search “Heizer Render OM Podcast,” and subscribe to get all our podcasts on your mobile device as soon as they come out!

Transcript

A Word document of this podcast will download by clicking the word Transcript above.

Instructors, assignable auto-graded exercises using this podcast are available in MyLab OM. See our earlier blog post with a recording of author and user Chuck Munson to learn how to find these, or contact your Pearson rep to learn more! https://www.pearson.com/en-us/help-and-support/contact-us/find-a-rep.html

OM in the News: Shein Markets Its Supply-Chain Technology to Global Brands

China-founded Shein has built a bargain fashion empire with a pioneering small-batch manufacturing model, reports The Wall Street Journal (March 21, 2024). Now it is planning to open that up to global brands and designers. It is calling the new initiative “supply chain as a service.”

Shein contracts with thousands of factories in China that churn out tens of thousands of new styles daily.

The move represents a shift in business strategy as Shein faces challenges in the U.S., its biggest market. Under the plan, Shein would make its supply-chain infrastructure and technology available to outside brands and designers, allowing them to leverage Shein’s system for testing out new fashion items in small batches and track how popular they are with consumers.

Shein has rapidly expanded from a discount Chinese apparel seller to a global fashion brand with the help of its small-batch, on-demand manufacturing model, and now sells to more than 150 countries. It has revolutionized fashion manufacturing as it contracts with thousands of factories in China that churn out tens of thousands of new styles daily. It places orders to suppliers to be delivered in days, relies on real-time data to quickly analyze demand and replenishes orders as needed. That cuts down on the cost for storage and limits inventory waste, a primary reason for its ultralow prices.

By making its supply-chain ecosystem more widely available to brands, Shein is refocusing on its powerful capabilities to manufacture and distribute fashion products efficiently.

Shein’s popularity in the U.S. has drawn the attention of lawmakers, who have pressed Shein to address whether it sources cotton from China’s Xinjiang region, where the U.S. has accused Chinese authorities of committing genocide and of using forced labor in its repression of mostly Muslim Uyghurs, allegations Beijing denies. Shein has said it has a “zero-tolerance policy” for forced labor.

Classroom discussion questions:

What is “supply chain as a service”? Why is Shein offering this service?
How has Shein revolutionized the apparel industry?

OM in the News: Walmart and “On-time, In-full” Shipments

This is the latest shift in a logistics effort that has historically left companies scrambling to meet the retail giant’s demands.

Walmart wants suppliers to deliver shipments on time 90% of the time and in full 95% of the time, down from a 98% benchmark for both measures set in 2020 amid a surge in consumer demand. The change marks a significant lowering of Walmart’s “on-time, in-full” (or OTIF) thresholds that are meant to increase the efficiency of Walmart’s sprawling U.S. logistics network of distribution centers serving the company’s thousands of stores.

Walmart has been working to get tighter control over its inventory as it fulfills more online orders from its stores and competes on home-delivery speed with e-commerce giant Amazon.com. Vendors that fall short of Walmart’s on-time, in-full targets face fines worth 3% of the cost of the goods that didn’t arrive on time or in full.

Walmart last shifted its thresholds in September 2020, when it tightened the requirements as supply-chain disruptions left many store shelves empty of high-demand products during the Covid-19 pandemic. The latest change comes as the retailer returns to more normal ordering patterns after years of struggling with sharp fluctuations in stocking levels during the pandemic. The greater equilibrium in supply chains has helped relieve pressure on suppliers.

Consumer packaged-goods vendors delivered an average of 84% of orders on time in 2023. Walmart’s lowered thresholds should be welcome news to vendors that have struggled to meet the 98% benchmarks. “Very, very rarely do things go perfectly as planned with deliveries. Trucks break down or get caught in traffic, and orders are sometimes packed with the wrong quantity and mix of items, such as orange-flavored soda instead of grapefruit,” said one industry expert.

Classroom discussion questions:

Why is Walmart changing its OTIF policy?
How does impact suppliers?

OM in the News: Retailers, Rising Theft and Shrinkage

As retailers report on the busy holiday shopping season, operations managers will be trying to get more understanding into shrinkage and theft, reports The Wall Street Journal (Jan. 9, 2024). The stores are fighting a growing wave of theft, cutting into profits that were already under pressure. But theft is just one contributor to shrink, the industry term for the difference between inventory on the books and what’s physically on hand. Lost or damaged goods and inaccurate records also play a part.

Shrink is now one of the most frequently discussed topics among management at Home Depot, said the firm’s CFO, having moved onto its list of top priorities two years ago. That focus hasn’t changed even though some mitigation efforts, such as locking up certain items and using live-view parking lot cameras, are in place.

The higher shrink may partly reflect a return to prepandemic norms rather than entirely new trends in theft. Reduced visits to physical stores starting in 2020 simultaneously decreased the opportunities for theft, an effect that dissipated as shoppers stepped out of their houses again.

Dollar General’s gross profit rate, or its profit as a percentage of net sales, fell 5% last quarter, due primarily to increased inventory shrink, more markdowns and lower inventory markups. Shrink is a roughly 100-basis-point headwind for Dollar General. Dick’s Sporting Goods expects shrink’s impact on its gross margin to be roughly 50 basis points higher in its current fiscal year compared with 2022.

Retailers have said they are responding by adding security personnel and technology, locking up goods and closing hard-hit stores. Target, which last year said that shrink was expected to cut into profitability by more than $500 million, closed nine stores, citing higher theft and safety concerns for shoppers and workers. Nike closed one of its Portland stores in 2022 amid issues with theft. Academy Sports & Outdoors is using locked shelves for certain items and outfitting some departments that have seen higher shrink, such as the baseball bat section, with sensors that indicate when people linger in an area. Some retailers, such as Costco, are less exposed to theft for reasons including that they sell larger, harder-to-steal products, and stores are laid out with one primary entrance and exit.

Classroom discussion questions:

Why is this an OM issue?
What would you do, as a supermarket manager, to cut shrink?