3 Supply Chain Contingency Planning Tips for Medical Device Companies
Scott Hothem • July 16, 2014
The recent months have brought some intense weather to all corners of our country. From the “Polar Vortex” last winter to violent tornadoes across the Midwest to Hurricane Arthur, each new day and week holds something new and potentially challenging. The only thing constant about weather is change. Theses volatile climate patterns unfortunately bring more than wind, snow, rain and lightning. Unfortunately these events cause a spike in emergency room and hospital visits. There have already been 41 tornado fatalities in 2014, according to NOAA. In fact during the Polar Vortex, Modernhealthcare.com reported that hospitals in Detroit brought in additional staff on multiple occasions to treat ER patients.
To make things more challenging, these additional visits and demands on hospital staffs and medical groups are often coupled with constraints on resources and accessibility. Over the 4th of July weekend, Hurricane Arthur left over 40,000 people with power and even caused a part of North Carolina Hwy. 12 to buckle on Hatteras Island. Last winter’s frigid temperatures and precipitation forced numerous surgeries and procedures to be rescheduled or cancelled. While organizations have contingency plans and redundancies in place to account for these scenarios, what back up strategy is there to account for supply chain complications?
The timely and precise demands that define medical device logistics needs to be maintained, especially in times of great need. Investing the time, energy and resources into contingency planning is like buying insurance. Hopefully you’ll never need it, but having the plans and process in place when these challenges arise can be the difference between life and death. These 3 elements can be implemented into your medical device supply chain, allowing your organization to persevere in the most difficult times.
- Be pre-emptive: While weather plays a major role in the disruption of services and the addition of constraints on resources, there are many other factors that could disrupt your supply chain. Manmade disasters, business decisions and governmental factors, just to name a few. However by having a finger on the pulse of what is happening around your organization can allow you to forecast possible problems. Notifying the key logistical partners that make up your supply chain is key. Ensure everyone is on the same page and ready to find answer to potential questions.
- Increase your essential supplies: To combat any lags or disruptions to your supply chain, having an abundance of the most necessary and important supplies stocked and accessible is crucial. Any device that you’ve been without in a similar situation should be maintained at a higher level to prevent a recurrence. While your bottom line is still a major consideration, you don’t have to throw your inventory management plan out of whack, but you do need to account for any delays.
- Supplier audits: This is a key element in maintaining visibility. Understanding and seeing the process your logistic partners leverage, and more importantly the results, can show the imperative steps to protect it in an emergency, as well as where other resources can be pulled to create a lean, agile fulfillment plan when necessary.
Supply chain contingency is a key element within your overall strategy. Identifying and responding to potential risks can mitigate a substantial threat to not only your operations, but your community. In an Inbound Logistics survey, 73% of participating companies claimed to have experienced a supply chain disruption. 32% of those said it took over 1 month to recover. Working closely with your supply chain personnel and partners is a critical step in preparing for the worst. With a focus on visibility and a track record of results, Barrett Distribution Centers has the technology, man-power and resources to play a key role in your contingency planning.
Recent Blog Posts
As your business grows, the warehouse that once supported your operations may start holding you back. What worked when you were shipping a few hundred orders a week may no longer be able to keep pace with rising order volumes, expanding sales channels, or increasing customer expectations. Recognizing the warning signs early can help you avoid fulfillment disruptions, rising costs, and dissatisfied customers. Here are seven indicators that it may be time to evaluate a new warehouse or 3PL partner. 1. Orders Are Taking Longer to Ship Today's customers expect fast, reliable delivery. If order processing times are increasing or you're struggling to meet shipping deadlines, your warehouse may have reached its capacity. Delays can impact customer satisfaction, retailer scorecards, and your brand's reputation. At Barrett Distribution, our facilities are supported by advanced warehouse management technology and engineered processes designed to maintain fast, accurate fulfillment as order volumes grow. 2. Inventory Accuracy Is Becoming a Challenge Frequent inventory discrepancies, stockouts, or overselling are often signs that your current operation lacks the systems and controls needed to scale. Modern warehouses should provide real-time inventory visibility, robust cycle counting programs, and reliable lot and expiration tracking where required. Barrett combines these inventory controls with customer reporting and analytics to help businesses make informed supply chain decisions. 3. You're Selling Across More Channels Many businesses now serve retailers, ecommerce customers, marketplaces, and wholesale distributors simultaneously. If your warehouse struggles to manage different order requirements, routing guides, or compliance standards, it may not be equipped for true omnichannel fulfillment. Barrett specializes in supporting both B2B and direct-to-consumer fulfillment from the same network, helping brands maintain consistent service levels across every sales channel. 4. Your Warehouse Can't Scale with Seasonal Demand Peak seasons shouldn't require scrambling for labor or turning away business. A warehouse partner should have the space, workforce, and operational processes to scale alongside your business during promotions, product launches, and holiday demand. With more than 6 million square feet of warehouse space across multiple U.S. markets, Barrett provides customers with the flexibility to grow without constantly worrying about capacity constraints. 5. You Have Limited Visibility into Your Operations If you're relying on spreadsheets or waiting for someone to send reports, you're missing valuable opportunities to improve performance. Today's logistics operations should provide real-time access to inventory, order status, shipping metrics, and key performance indicators. Barrett's customer portal and embedded analytics give customers greater visibility into their operations, helping them identify trends and make data-driven decisions. 6. Transportation Costs Continue to Rise Your warehouse location has a direct impact on shipping costs and delivery times. If you're shipping nationwide from a single facility that no longer aligns with your customer base, transportation expenses can quickly increase. Barrett's nationwide fulfillment network allows businesses to position inventory closer to customers, reducing transit times while helping optimize parcel and freight costs. 7. Your 3PL Feels Like a Vendor, Not a Partner Perhaps the biggest sign you've outgrown your current warehouse is the relationship itself. A strong 3PL should do more than process orders—it should proactively recommend improvements, communicate regularly, and help your business adapt as it grows. At Barrett, every customer is supported by dedicated operations teams, strategic account management, and a culture of continuous improvement. From onboarding through ongoing optimization, the focus is on building long-term partnerships that evolve alongside each customer's business. Is It Time to Reevaluate Your Fulfillment Strategy? Growth is a good problem to have—but only if your logistics operation can keep up. If any of these signs sound familiar, it may be time to assess whether your current warehouse is supporting your long-term goals. With more than 80 years of experience, a nationwide network of strategically located facilities, advanced technology, and expertise across ecommerce, retail, and omnichannel fulfillment, Barrett Distribution helps businesses scale with confidence. The right warehouse partner doesn't just store inventory—it becomes an extension of your business, helping you deliver a better experience to your customers every step of the way.
When businesses think about major U.S. logistics hubs, cities like Los Angeles, Chicago, and Dallas usually come to mind. However, Memphis has quietly become one of the country's most strategic locations for distribution. Its central geography, world-class transportation infrastructure, and access to major parcel networks make it an ideal location for companies looking to improve delivery speed while controlling costs. For businesses with customers across the country, Memphis offers a unique advantage. Its location allows products to reach much of the U.S. within one to two days by ground, helping brands reduce transit times without the complexity of operating multiple distribution centers. As customer expectations for faster shipping continue to rise, a centrally located warehouse can make a measurable difference in both service levels and transportation spend. A key reason Memphis stands out is its role as home to the FedEx World Hub. The city's direct connection to one of the largest air cargo operations in the world supports faster parcel movement, later shipping cutoffs, and greater flexibility for ecommerce and omnichannel fulfillment. Combined with major interstate highways, rail service, and Mississippi River access, Memphis provides businesses with multiple transportation options that strengthen supply chain resilience. Beyond transportation, Memphis remains an attractive market because of its competitive operating costs. Warehouse space, labor availability, and room for expansion often make it a more economical choice than many coastal markets. For growing companies, this creates an opportunity to scale operations without significantly increasing logistics costs. At Barrett Distribution, we've recognized the strategic value of Memphis for years. Our five Memphis-area facilities are designed to support both B2B and direct-to-consumer fulfillment, allowing customers to serve retail partners, ecommerce shoppers, and marketplaces from a centrally located network. Backed by advanced warehouse management technology, transportation management systems, real-time inventory visibility, and value-added services, our Memphis operations help customers improve efficiency while maintaining the flexibility to grow. For brands looking to strengthen their national distribution strategy, Memphis offers a compelling combination of speed, connectivity, and scalability. Paired with Barrett's nationwide network of fulfillment centers, businesses can build a distribution strategy that shortens delivery times, reduces transportation costs, and positions them for long-term growth.
If you work in supply chain, you've probably heard the term omnichannel fulfillment so many times that it's started to lose meaning. It's become one of those logistics buzzwords that gets thrown around in conference sessions and sales presentations. But for brands trying to grow, omnichannel fulfillment isn't a trend—it's an operational reality. A decade ago, many brands sold through one or two channels. Today, a single brand might be shipping direct-to-consumer orders, replenishing Amazon inventory, fulfilling wholesale accounts, and managing retail compliance requirements simultaneously. The challenge isn't opening new sales channels. The challenge is supporting all of them without creating separate supply chains for each one. That's what omnichannel fulfillment really means in 2026. It's the ability to manage retail, ecommerce, marketplace, and wholesale fulfillment through a unified operation that provides inventory visibility, operational flexibility, and a consistent customer experience. And that's easier said than done. Many growing brands find themselves adding channels faster than they add infrastructure. What started as an ecommerce fulfillment operation suddenly needs to support retailer routing guides, EDI requirements, compliance labeling, and increasingly complex inventory management. Before long, inventory gets fragmented, processes become reactive, and fulfillment starts slowing growth instead of enabling it. The brands that navigate this successfully tend to have one thing in common: they stop thinking about fulfillment as a warehouse function and start treating it as a strategic part of their business. That's where the right logistics partner can make a significant difference. At Barrett, omnichannel fulfillment has been at the core of our business for decades. We support brands across retail, ecommerce, wholesale, and marketplace channels from a nationwide network of distribution centers designed to handle the complexities of modern commerce. What makes omnichannel fulfillment work isn't simply having warehouse space. It's having the systems, processes, and expertise to manage different order profiles, customer requirements, and service expectations within a single operation. A direct-to-consumer order and a retail replenishment shipment may originate from the same inventory, but they require very different workflows. One may involve individual pick-and-pack fulfillment with rapid delivery expectations, while the other demands strict retailer compliance, ASN management, and precise routing instructions. Barrett's operations are built to support both. Our technology ecosystem connects warehouse management, transportation management, customer reporting, and trading partner integrations to provide visibility across the supply chain. Combined with dedicated account management and continuous improvement initiatives, this allows customers to scale into new channels without constantly rebuilding their logistics infrastructure.The result is a fulfillment operation that can adapt as a business grows. Whether a brand is expanding into major retail accounts, increasing ecommerce volume, launching on Amazon, or managing all three simultaneously, the goal remains the same: create a seamless experience for customers while maintaining operational efficiency behind the scenes. Because in today's market, customers don't think about channels. They simply expect products to arrive on time and accurately. The companies that succeed in 2026 will be the ones that can deliver that experience consistently, regardless of where the order originated. That's the promise of omnichannel fulfillment—and it's why more brands are looking for logistics partners that can do more than move inventory. They're looking for partners that can help them grow.
