John Johnson joined the DC Velocity team in March 2004. A veteran business journalist, John has over a dozen years of experience covering the supply chain field, including time as chief editor of Warehousing Management. In addition, he has covered the venture capital community and previously was a sports reporter covering professional and collegiate sports in the Boston area. John served as senior editor and chief editor of DC Velocity until April 2008.
Zipcar has made a name for itself by renting cars to drivers who need wheels on demand—a couple of hours one day, maybe a full day the next. By tapping into a wireless network, Zipcar members can locate vehicles on a moment's notice and be on the road within minutes.
Company executives say that many of its customers have achieved transportation nirvana—more than 30 percent have either sold their cars or have decided not to buy one. The concept allows customers to pay for only the amount of time they drive the car, without having to worry about nuisances like insurance and maintenance.
A similar model is attracting the interest of distribution managers who want to cut down on the cost of maintaining a fleet of forklifts. Some companies that lease their lift trucks are asking their fleet management providers for a "power by the hour" option, as some truck makers refer to the concept.
That's just one of several developments that are leading more companies to outsource management of their forklift fleets to truck manufacturers and third parties. They're not only saving plenty—in terms of time, money, and maintenance. They're also getting access to technologies and support services that can help them improve the safety and efficiency of their operations.
Pay as you go
It's only recently that the technology that makes pay-by-the-hour fleet leasing possible became commercially available. RFID and sensor technologies, aided by improved, lower-cost telemetry, allow fleet managers to monitor exactly when a lift truck is activated and when it is shut down. Drivers activate the monitoring system by entering a unique identification number for each truck.
The practice of paying for the amount of time when vehicles are actually in use is expected to become a major trend, especially as companies continue to outsource fleet management and concentrate on their core competencies. Right now, though, it's just getting started.
"We quote a ton of business each week, and very few are asking for a per-hour cost structure," says Van Clarkson, director of fleet management at Hyster, a lift-truck manufacturer that also offers fleet management services. "But it's something we expect to see become more common going forward. And we have customers who are actually using the technology today."
The most likely users of "pay as you go" forklifts are companies whose operations don't require the equipment to run at all times. The hourly system is ideal for the logistics sector, especially third-party logistics service providers that experience peaks and valleys in their work flow and may use some equipment for limited periods.
"They've got their core fleet and units that they use every day, but they may take on a new client and need a few extra pieces to support their core fleet," explains Will van Ness, fleet finance manager for Yale Materials Handling. "A unit could sit on the sidelines and only be put into use on demand. It might sit idle 75 percent of the time, but once the hour meter starts, we collect the data and we can invoice the customer monthly, quarterly, or however the customer chooses."
What's your hot button?
Automated fleet management systems offer a host of benefits, such as tracking and reporting, automated preventivemaintenance schedules, consolidated billing, and management of asset utilization. They can also simplify Occupational Safety and Health Administration (OSHA) compliance through automating the safety check procedure that each driver must go through prior to starting a vehicle.
A recent poll conducted by DC VELOCITY found that customers' opinions varied widely when it came to which of these capabilities they considered most useful. For example, while 47 percent of the respondents said that OSHA compliance was a major benefit of fleet management systems, 27 percent said they did not use their systems for that purpose. Preventive maintenance and asset utilization were rated among the more useful capabilities of fleet management systems.
Those results, no doubt, reflect differences in priorities. "Every customer has its own 'hot button'," says Matt Ranly, senior marketing product manager for Crown Equipment Corp., which offers a wireless fleet management system called InfoLink. "One customer might be interested in monitoring impacts or impact reporting, and the next customer may be all about OSHA compliance and making sure that only authorized people are driving trucks. The next guy might be most concerned with maximizing fleet utilization," he observes.
Sean Bennett's hot button is making sure his forklift operators adhere to the safety rules in place at his distribution center. After installing Crown's InfoLink system to monitor forklift impacts, though, he realized that the drivers weren't being as careful as he had thought.
Bennett is senior financial operations support manager at MBM Corp., a customized-food distributor with 32 distribution centers around the country. The company has installed InfoLink on 48 pieces of forklift equipment at its 170,000-square-foot DC in Rancho Cucamonga, which is located in Southern California's Inland Empire.
When InfoLink was first installed, Bennett simulated impacts, such as those that would result from driving into a pole or racking, so management would understand the metrics that would be used for evaluating the seriousness of those events. Soon after the monitoring program was rolled out to drivers, it became clear that some operators were experiencing impact events at a much higher rate than management had expected.
So much was going on, in fact, that Bennett's team initially was collecting an unmanageable amount of data. After tweaking the system, MBM is now able to monitor and analyze the data it receives. As a result of those enhanced reporting capabilities, managers today are able to address impact events with individual drivers.
The fleet management system turned out to be a good investment. "Now that we have started to monitor the equipment's activity and seize opportunities to improve training for individual operators, we expect to see a reduction in repair and maintenance expense on our equipment and racks," Bennett says.
But for MBM, calculating payback from the fleet management system is more than just a financial matter. The company takes great pride in its safety record, and it expects that InfoLink will help it enhance its performance. For example, MBM plans to use the data to determine how many forklift impacts are caused by drivers with less than a year of experience, and how many involve veteran drivers. The company will also use the information to evaluate its safety and training program and to make necessary adjustments.
"We always want safety to be our primary concern," Bennett says. "Because InfoLink is on our equipment, we think it creates awareness, and this awareness will help our operators to be careful how they drive the unit and to be safety-conscious."
More room for growth
It appears that there is plenty of opportunity for providers of fleet management services to expand their customer base down the road. In the DC VELOCITY poll, only 38 percent of the respondents reported that they were already using a fleet management system. That percentage seems likely to grow: Of the 80 percent who said that they planned to purchase new lift trucks in the next 12 months, half indicated that they planned to attach a request for proposal (RFP) for fleet management services to their purchase orders.
Those numbers aren't surprising, given that fleet management services offer so many potential benefits and new technology-based capabilities like by-the-hour leasing are coming online all the time. But there may be something more fundamental behind the fleet outsourcing trend: The need to focus on the right business priorities.
"One of the reasons why more and more of our customers are getting into outsourcing fleet management is that they want to concentrate on their core business," says Hugh Quinnell, national manager, major accounts, parts, and service operations at Toyota Material Handling, which unveiled a new fleet management program in June. "Customers are able to focus on the nuts and bolts of their business and let the experts handle the things that are not part of their core business."
Fruit company McDougall & Sons is running a tighter ship these days, thanks to an automated material handling solution from systems integrator RH Brown, now a Bastian Solutions company.
McDougall is a fourth-generation, family-run business based in Wenatchee, Washington, that grows, processes, and distributes cherries, apples, and pears. Company leaders were facing a host of challenges during cherry season, so they turned to the integrator for a solution. As for what problems they were looking to solve with the project, the McDougall leaders had several specific goals in mind: They wanted to increase cherry processing rates, better manage capacity during peak times, balance production between two cherry lines, and improve the accuracy and speed of data collection and reporting on the processed cherries.
RH Brown/Bastian responded with a combination of hardware and software that is delivering on all fronts: The new system handles cartons twice as fast as McDougall’s previous system, with less need for manual labor and with greater accuracy. On top of that, the system’s warehouse control software (WCS) provides precise, efficient management of production lines as well as real-time insights, data analytics, and product traceability.
MAKING THE SWITCH
Cherry producers are faced with a short time window for processing the fruit: Once cherries are ripe, they have to be harvested and processed quickly. McDougall & Sons responds to this tight schedule by running two 10-hour shifts, seven days a week, for about 60 days nonstop during the season. Adding complexity, the fruit industry is shifting away from bulk cartons to smaller consumer packaging, such as small bags and clamshell containers. This has placed a heavier burden on the manual labor required for processing.
Committed to making its machinery and technology run efficiently, McDougall’s leaders decided they needed to replace the company’s simple motorized chain system with an automated material handling system that would speed and streamline its cherry processing operations. With that in mind, RH Brown/Bastian developed a solution that incorporates three key capabilities:
Advanced automation that streamlines carton movement, reducing manual labor. The system includes a combination of conveyors, switches, controls, in-line scales, and barcode imagers.
A WCS that allows the company to manage production lines precisely and efficiently, with real-time insights into processing operations.
Data and analytics capabilities that provide insight into the production process and allow quick decision-making.
BEARING FRUIT
The results of the project speak for themselves: The new system is moving cartons at twice the speed of the previous system, with 99.9% accuracy, according to both RH Brown/Bastian and McDougall & Sons.
But the transformational benefits didn’t end there. The companies also cite a 130% increase in throughput, along with the ability to process an average of 100 cases per minute on each production line.
Artificial intelligence (AI) and the economy were hot topics on the opening day of SMC3 Jump Start 25, a less-than-truckload (LTL)-focused supply chain event taking place in Atlanta this week. The three-day event kicked off Monday morning to record attendance, with more than 700 people registered, according to conference planners.
The event opened with a keynote presentation from AI futurist Zack Kass, former head of go to market for OpenAI. He talked about the evolution of AI as well as real-world applications of the technology, furthering his mission to demystify AI and make it accessible and understandable to people everywhere. Kass is a speaker and consultant who works with businesses and governments around the world.
The opening day also featured a slate of economic presentations, including a global economic outlook from Dr. Jeff Rosensweig, director of the John Robson Program for Business, Public Policy, and Government at Emory University, and a “State of LTL” report from economist Keith Prather, managing director of Armada Corporate Intelligence. Both speakers pointed to a strong economy as 2025 gets underway, emphasizing overall economic optimism and strong momentum in LTL markets.
Other highlights included interviews with industry leaders Chris Jamroz and Rick DiMaio. Jamroz is executive chairman of the board and CEO of Roadrunner Transportation Systems, and DiMaio is executive vice president of supply chain for Ace Hardware.
Jump Start 25 runs through Wednesday, January 29, at the Renaissance Atlanta Waverly Hotel & Convention Center.
A lithium refinery that broke ground this week on construction of a $1.2 billion plant in Oklahoma will soon become one of the nation’s largest factories for producing materials for batteries, according to officials with Connecticut-based Stardust Power Inc.
In December 2024, the company said it had acquired the 66-acre site for the refinery in Muskogee, Oklahoma, as well as the right of first refusal for future expansion on an adjacent 40-acre parcel of land. In choosing those plots, it cited the location’s proximity to the country’s largest inland waterway system, robust road and rail networks, and a skilled workforce rooted in the oil and gas sector.
Up next, the project will be developed in two phases, with the first phase focused on constructing a production line capable of producing up to 25,000 metric tons per annum. The second phase will add a second production line, bringing the total capacity to 50,000 metric tons per annum.
As it moves into the construction stage of the project, the company said it would follow sustainable standards, including responsible corporate practices, climate action, and the energy transition. “Our lithium refinery will be crucial for addressing U.S. national security and supply chain risks. By onshoring critical mineral manufacturing, we are helping to sustain America’s energy leadership,” Stardust Power Founder and CEO, Roshan Pujari, said in a release. “At a time when foreign entities of concern are attempting to consolidate critical minerals, Stardust Power is proud to play a key role in safeguarding American interests and supporting Oklahoma’s local economy,” Pujari said.
Local officials cheered the project for the hundreds of jobs it is projected to create once fully operational, and for its role in helping strengthen the U.S. supply chain for critical minerals by reducing the nation’s reliance on China for the production of critical rare earth elements.
The new cranes are part of the latest upgrades to the Port of Savannah’s Ocean Terminal, which is currently in a renovation phase, although freight operations have continued throughout the work. Another one of those upgrades is a $29 million exit ramp running from the terminal directly to local highways, allowing trucks direct highway transit to Atlanta without any traffic lights until entering Atlanta. The ramp project is 60% complete and is designed with the local community in mind to keep container trucks off local neighborhood roads.
"The completion of this project in 2028 will enable Ocean Terminal to accommodate the largest vessels serving the U.S. East Coast," Ed McCarthy, Chief Operating Officer of Georgia Ports, said in a release. "Our goal is to ensure customers have the future berth capacity for their larger vessels’ first port of calls with the fastest U.S. inland connectivity to compete in world markets."
"We want our ocean carrier customers to see us as the port they can bring their ships and make up valuable time in their sailing schedule using our big ship berths. Our crane productivity and 24-hour rail transit to inland markets is industry-leading," Susan Gardner, Vice President of Operations at Georgia Ports, said.
It appears to have found that buyer in Aptean, a deep-pocketed firm that is backed by the private equity firms TA Associates, Insight Partners, Charlesbank Capital Partners, and Clearlake Capital Group.
Through the purchase, Aptean will gain Logility’s customer catalog of over 500 clients in 80 countries, spanning the consumer durable goods, apparel/accessories, food and beverage, industrial manufacturing, fast moving consumer goods, wholesale distribution, and chemicals verticals.
Aptean will also now own the firm’s technology, which Logility says includes demand planning, inventory and supply optimization, manufacturing operations, network design, and vendor and sourcing management.
“Logility possesses years of experience helping global organizations design, build, and manage their supply chains” Aptean CEO TVN Reddy said in a release. “The Logility platform delivers a mission-critical suite of AI-powered supply chain planning solutions designed to address even the most complex requirements. We look forward to welcoming Logility’s loyal customers and experienced team to Aptean.”