Mohawk Industries saves over $9M annually by optimizing their biggest expense areas with Samsara data

With Samsara, Mohawk closes the gap in planned vs. actual routes to reduce mileage by 4.2 million miles and improve driver pay processes. Samsara reporting and AI enable efficiency gains across every aspect of their supply chain, ultimately improving profitability and their customer experience.

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Meet Mohawk Industries

Mohawk needed a feedback mechanism across their three fleets

Running over one million miles each week, Mohawk Industries is the largest flooring manufacturer in the world. Their supply chain operates three distinct fleets: first mile—serving the factories and ports, middle mile—over the road trucking division, and final mile—delivering product to their customers. Additionally, each fleet operates on a different TMS to meet their specific needs. Before Samsara, this meant data collection was nearly impossible—Mohawk lacked visibility into their vehicle locations, miles driven, and routing accuracy.

Looking to update and consolidate legacy technology, they required a connected platform to drive digital transformation across the organization and increase efficiency. Specifically, Mohawk sought a solution to improve their planned vs. actual routing, a manual process that impacted every aspect of their business, including customer service and driver payments. The Mohawk team also looked to install dash cams in their trucks for the first time to improve driver safety and get context into incidents.

ANDY YEAROUT

Connecting Mohawk’s three fleets into one cohesive supply chain

“We chose Samsara for the continuous innovation and availability of new solutions,” said Matt Kin, Director of Delivery Operations. “Samsara’s seamless integration with our current systems made the transition simple.” When rolling out Samsara across their supply chain, they phased their approach, beginning with safety to demonstrate fast and clear ROI. Then, they targeted their largest expense areas—labor, fuel, and maintenance—informed by Samsara data.

By analyzing and optimizing just a few of their biggest cost areas, like routing and idling, they’ve driven efficiency gains across their entire operation. Mohawk also significantly simplified their driver experience and unified their three fleets using integrations to standardize their supply chain. “Samsara gives us the opportunity to work smarter, not harder,” said Yearout. “Instant feedback allows us to make adjustments in real time, whereas we completely lacked a feedback mechanism before.”

Saving $7.75M by improving planned vs. actual routing

Previously, drivers manually tracked routes, miles, and stops through written logs, which meant they couldn’t accurately analyze planned vs. actual routing. With Samsara Fleet Telematics, the team has fully digitized their routing process and improved route accuracy. As a result, Mohawk reduced miles driven by 4.2 million, saving $7.75M across their entire fleet. They also cut idling by 12%, leading to $600,000 in fuel savings.

Reducing admin work by 75% with simplified supply chain management

Before Samsara, Mohawk’s supply chain functioned as three separate fleets from transporting raw materials to delivering finished products to customers. Using Samsara’s open API and TMS integrations, like McLeod, Mohawk unified their operations and standardized workflows across their supply chain, reducing administrative work by 75%.

MATT KIN

AI-powered, self-coaching tools reduce accidents by 13%

Prior to installing Samsara AI Dash Cams, Mohawk had limited visibility into driver safety, and no video evidence to exonerate drivers from not-at-fault incidents. Since deploying Samsara AI Dash Cams across their fleet, Mohawk coaches behaviors in real time to achieve a 54% reduction in speeding, 17% reduction in collision risk, and 9% reduction in harsh driving—ultimately contributing to a 13% decrease in crashes.

Rightsizing their trailer fleet to save $500,000 annually

Before Samsara, Mohawk manually tracked their 2,500 trailers. With Smart Trailers, they have access to granular utilization and trailer health data which they use to monitor and rightsize their fleet. Since implementation, Mohawk removed 200 trailers from their fleet, saving $500,000 annually. They reinvest those savings back into the business to purchase new equipment, decreasing their average asset age by two years.

Digital workflows reduce HOS violations by 68% and route communication time by 93%

Digitizing processes for their workforce was no small task, but Mohawk leveraged Samsara to quickly and efficiently connect their data within one platform. As a result of digitizing pen-and-paper processes, Mohawk has saved days of work—evolving their driver pay system to be nearly instantaneous—transformed ELD compliance to reduce violations by 68%, and simplified their once complex dispatch process to cut communication time by 93%.