SHIPPED!

BackOps AI

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SHIPPED! is a podcast for operations leaders in logistics and supply chain. Hosted by Sean McCarthy, Co-Founder & CEO at BackOps.ai, each episode features candid conversations with VPs of Operations, Customer Success Directors, and COOs about the real challenges they face – handling shipping issues, managing customer problems when deliveries go wrong, and keeping customers happy.

23 июн.

$10 orders that cost $30: the split-shipment problem in store-plus-DTC retail

Frank von Oldenburg has run logistics for semiconductors, train brakes, printers, and now apparel, starting on the night shift doing import entries and working up to VP of Logistics at DXL Group. His operating thesis: a widget is a widget, until the day it's a 5,000-pound steel coil that will derail a train if it uncoils. He tells Sean why he repeatedly took lateral and lower-paying moves to gain operational range over title, and why you owe the company the routing analysis even when it confirms the decision you'd already made: he walks through the math on why DXL stays routed around the Cape of Good Hope, where shifting West Coast saves four days at three times the freight. The sharpest material is on running stores and direct-to-consumer at once. Frank is solving a live problem where 30% of orders split across a DC and multiple stores, turning a $10 shipment into $30, and explains why he won't cancel the order anyway. He also makes a contrarian case on AI and talent: the entry-level analyst work is the first to go, which quietly removes the training ground that produces the next senior operator. Topics discussed: Taking lateral and lower-paying moves to gain operational range over title Where "a widget is a widget" breaks: chartered vessels, cold storage, steel coils on rail Doing the routing analysis even when you keep the same decision (Cape of Good Hope vs. West Coast cost math) Matching freight spend to commodity margin: air-shipping chips vs. protecting apparel margin Why understaffed teams take PO shortcuts that void SAP and Oracle investments The gap WMS and TMS can't close: the side conversations and emails where problems actually get worked Balancing a committed ocean allocation against spot-market opportunism Optimizing for consistent in-store availability over winning on rate Inventory placement economics when DTC mix swings from 20% to 40%+ The 30% split-shipment problem and its true landed cost Same-day delivery as an open question for non-urgent apparel How AI removing entry-level analyst work erodes the senior talent pipeline

30 мин.
22 апр.

Why AI should be a recommendation, not a dictation: lessons from 12,000 DSD routes | Jeffrey Hendrix (Bimbo Bakeries)

Jeffrey Hendrix started on a bread route at 19, delivering to grocery stores at 3am, and didn't finish his undergraduate degree until he was 35. By 47 he had a doctorate and was running commercial strategy for a company with 83% U.S. household penetration and 12,000 routes on the street. The education wasn't the point, applying theory in real time to decisions he was already making was. In this episode, Jeff gets specific about how Bimbo Bakeries is using hourly SKU-level scan data to close the loop between shelf demand and bakery production, why he believes AI should function as a strategic advisor rather than a decision maker, and how their DSD model creates a structural cost and service advantage that warehouse-delivered suppliers can't match. Topics discussed: How scan-based trading shifts inventory ownership and payment timing versus traditional invoicing Using hourly store-SKU data combinations to trigger same-day upstream production signals The 24-hour replenishment loop from shelf signal to delivery correction Why DSD operators hold a defensible last-mile advantage during weather events and disruptions AI as recommendation, not dictation, and what that means for frontline decision rights Digital purchase penetration crossing 20% and its pressure on trade spend and out-of-stock risk The data trust problem between suppliers and retailers before any AI overlay can work Building value chains versus optimizing supply chains and why the distinction matters operationally

31 мин.
10 мар.

How Brinker sustains 20% growth: Supply visibility over demand forecasting | James Butler

James Butler rebuilt Brinker International's supply chain around a contrarian principle: optimizing supply visibility beats perfecting demand forecasts. As SVP & Chief Supply Chain and Corporate Strategy Officer managing operations for Chili's and Maggiano's across 1,200+ restaurants, he's engineered a feedback architecture that converts operator friction into system-level improvements—sustaining 20% quarter-over-quarter growth for eight consecutive quarters. His operational philosophy rejects the traditional supply chain mandate of minimizing cost. Instead, he's structured his organization to eliminate downstream friction—whether that's a restaurant manager spending 10 minutes filing a quality report or manufacturers losing visibility across multiple disconnected warehouse systems. From deploying voice AI for instant quality escalation to implementing every-six-weeks restaurant immersion as a senior leader diagnostic, James demonstrates how systematic operator listening creates the adaptive capacity modern supply chains require. Topics discussed: Prioritizing supply position visibility and rapid replan capability over demand forecasting accuracy Structuring deliberate cross-functional feedback consolidation to separate signal from one-off noise Reorienting supply chain from cost optimization mandate to friction reduction and growth enablement Implementing voice AI for quality reporting to eliminate 10-minute form-based operator burden Building multi-source, geographically proximate supplier redundancy without mass-production frozen inventory Scaling intentional two-to-three-day restaurant immersion cycles as executive-level operational diagnostic Evaluating external technology through friction-reduction lens rather than capability feature lists Codifying why initiatives succeed or fail to build institutional knowledge across transformation cycles

31 мин.
10 мар.

How face-to-face supplier visits cut costs 40-50% | Bryan Kryzda (Cove Brands)

Bryan Kryzda spends 6-8 weeks per year in China and Korea, cutting out trading intermediaries to negotiate directly with manufacturers. This approach recently delivered 40-50% cost reductions on identical products from existing suppliers—same quality, dramatically different economics. At Cove Brands, he's applying consulting, banking, and PE experience to transform a post-bankruptcy Amazon aggregator into a profitable portfolio of 14 brands in health, wellness, and home categories. His framework starts with finance as the operational backbone. While his team uses AI to compress inventory reconciliation cycles by a full week, the real impact is strategic: supply chain and finance teams now spend their time optimizing processes rather than chasing spreadsheet errors. He's partnering with a specialized AI firm rather than hiring in-house data engineers, deliberately avoiding the 2x headcount cost of building internal capabilities for technology that's still rapidly evolving. Topics discussed: Finance operations as first hire: closing books faster unlocks strategic capacity Manufacturer relationships through direct visits: eliminating middlemen for 40-50% cost reduction When founding teams hit capability limits during 3-15M revenue transitions AI implementation through specialized partners vs. in-house engineering economics Inventory reconciliation automation: week-faster closes free teams for higher-value work Technology adoption timing: waiting for market maturity vs. early adopter risk Tariff mitigation through supplier relationships and forward inventory positioning Consultant recommendations failing without honest team capability assessment Google Translate and cultural discomfort as business development tools Private equity operator evaluation: technical knowledge, relationship building, and execution hunger

30 мин.
10 мар.

How OpticsPlanet forecasts 1M+ SKUs: The 90-day prediction system that stocks items selling once

Managing over 1 million SKUs across 2,500 brands requires a forecasting system sophisticated enough to predict single-unit demand 90 days out. OpticsPlanet's approach: if the model predicts even one sale within that window, they stock it. High-velocity items get 45 days of supply maintained automatically. But when COVID sent demand through unpredictable cycles from 2020-2022, their systems couldn't factor in macroeconomic forces that would end social distancing or state-level assault weapons bans—so they manually overrode automation until markets stabilized. Alex Royzen explains how OpticsPlanet built an internal AI team running "Skunkworks" projects on forecasting and merchandising optimization—unusual for a company their size. Their adoption playbook: show skeptical buyers side-by-side performance of AI forecasts versus current methods using historical data, then deploy once trust is established. He describes visiting a distributor whose warehouse bins physically reorganize themselves based on velocity, always positioning faster-movers closer to packers. OpticsPlanet applies similar logic through ABCD velocity ranking without the capital investment. The foundation enabling all of this: a "measure, analyze, act" culture (literally written on their walls) where the CEO engages directly with junior staff on process improvements. Topics discussed: Automatic purchase orders triggered when AI predicts single-unit sales within 90 days Building internal AI "Skunkworks" teams for forecasting and merchandising at mid-market scale Historical data comparison methodology for earning stakeholder trust before AI deployment Self-reorganizing warehouse bin systems that physically move inventory by velocity Manual override protocols when algorithms can't factor macroeconomic disruptions ABCD velocity ranking as capital-efficient alternative to automated warehouse systems "Measure, analyze, act" cultural framework enabling junior staff to drive process improvements Data quality requirements for managing unfamiliar product categories without domain expertise

37 мин.
27 февр.

AI adoption without the hype: Using ChatGPT while staying skeptical of enterprise AI solutions

Most ops leaders won't tell you they're confused about their ICP. Zach Sands does. As VP of Operations at Pangaea, running both a DTC subscription skincare brand and a retail-heavy grooming line, he's using his podcast appearances as a live testing ground to figure out which pain points actually resonate. That level of honesty shapes his entire approach to AI: he's using ChatGPT as a research assistant while actively resisting the pressure to adopt solutions just because everyone else is. Zach's path from warehouse floor management to corporate supply chain roles at Lowe's and CPG brands gives him a specific lens on what's changing in operations leadership. The old "grit and sheer will" mentality that defined supply chain is being replaced by leaders who see technology as the strategic unlock, not a nice-to-have. He's watching this shift play out in real-time at Pangaea, where bundle flexibility and channel-specific strategies require staying nimble while macro uncertainty makes long-term bets harder. Topics discussed: Taking career opportunities when they appear regardless of personal timing constraints Approaching AI adoption as a thought partner for eliminating repetitive research tasks Evaluating technology investments against potential headcount additions before committing to either Maintaining inventory as individual SKUs with on-demand kitting to enable dynamic bundle shifts Structuring leadership time between front-line issue resolution and strategic root-cause analysis Targeting SNOP and planning functions as highest-probability wins for AI automation Reading fall Prime Day underperformance as potential consumer sentiment signal versus execution issue Building supply chain resilience through multi-sourcing rather than legacy single-supplier dependencies

33 мин.

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SHIPPED! is a podcast for operations leaders in logistics and supply chain. Hosted by Sean McCarthy, Co-Founder & CEO at BackOps.ai, each episode features candid conversations with VPs of Operations, Customer Success Directors, and COOs about the real challenges they face – handling shipping issues, managing customer problems when deliveries go wrong, and keeping customers happy.

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