Mark Solomon joined DC VELOCITY as senior editor in August 2008, and was promoted to his current position on January 1, 2015. He has spent more than 30 years in the transportation, logistics and supply chain management fields as a journalist and public relations professional. From 1989 to 1994, he worked in Washington as a reporter for the Journal of Commerce, covering the aviation and trucking industries, the Department of Transportation, Congress and the U.S. Supreme Court. Prior to that, he worked for Traffic World for seven years in a similar role. From 1994 to 2008, Mr. Solomon ran Media-Based Solutions, a public relations firm based in Atlanta. He graduated in 1978 with a B.A. in journalism from The American University in Washington, D.C.
No sector of transportation has been immune to the effects of the global economic downturn. But
perhaps no industry has taken it on the chin with greater ferocity than has air freight.
The worldwide collapse of air traffic, which began late last year and has extended into 2009, is
unprecedented in the industry's 60-plus years of existence. December 2008 volumes reported by the
International Air Transport Association (IATA) fell by 22.3 percent over December 2007.
Year-over-year volumes dropped by more than 20 percent in each of the next four months before
showing a slight improvement in May and June, when they declined 17.4 percent and 16.5 percent,
respectively.
The consensus is that the market has stabilized at current levels. But that is little solace for
an industry long accustomed to annual growth in the high single digits to low double digits. And
while things may improve somewhat as the year progresses, there isn't much hope for a recovery
before 2010.
Earlier this year, IATA predicted 2009 volume declines of 13 percent, and in June, the group
revised its forecast downward to 17 percent. That may be a little optimistic: Swiss freight
forwarding giant Panalpina predicts a 19-percent year-over-year contraction, noting that its
forecast includes data from freighter operators that aren't included in IATA's tabulations.
Stiff headwinds
It doesn't take a Harvard M.B.A. to understand what's going on. The recession has been global in
scope, and air freight's primary value is in connecting global supply chains. Companies are not only
shipping less, but many also now have a viable alternative to air in the form of
less-than-containerload (LCL) ocean services that are cheaper, faster, and more reliable than
ever before. Today, companies ranging from parcel carriers UPS and DHL to traditional truckers
like Con-way, Old Dominion Freight Lines, and Averitt Express are playing in the LCL market or
plan to soon enter the fray.
What's more, last summer's massive spike in oil prices forced businesses to re-examine their
offshore production strategies and the just-in-time inventory management model that relied on air
to rush goods to market over long distances. And ever-increasing security regulations have layered
additional costs onto an already premium-priced service.
While there may be multiple reasons for the weakness in air freight, there appears to be just
one remedy: a global economic rebound. But opinion is divided on whether an economic upturn could
turn the industry's fortunes around.
The Boeing Co., for instance, remains confident in air freight's long-term prospects, projecting
that global air-cargo traffic will grow by 5.4 percent a year over the next 20 years. "The air
cargo industry is supported by sound fundamentals—the imperative for speed, consumer product
innovation, and global industrial interdependence are key drivers—and new air trade routes
will expand service coverage," said Randy Tinseth, vice president, marketing of Boeing's commercial
airplanes unit, in a statement.
Others beg to differ. As they see it, a global economic recovery will not alter the structural
changes taking place that will work against air-freight's growth.
For one thing, lower production costs spurred by globalization and improved information
technology have led to reductions in the average value of many commodities. "The impact of
generalized price deflation will continue to depress the rate of air cargo growth," said Brian P.
Clancy, managing director of Arlington, Va.-based consultancy MergeGlobal Inc., in a report.
Price deflation typically forces managers to cut transportation costs to stay competitive. As the
most expensive transport mode, air is at a disadvantage to lower-cost alternatives like ocean on
international trade lanes, and to truck and intermodal services in the domestic U.S. trades.
"Our customers are asking why they should pay five times more for air freight than for ocean just
to save 10 days," says Julian Keeling, a 35-year industry veteran and founder of Los Angeles-based
Consolidators International. Consolidators' business was built around negotiating cargo space
aboard aircraft for small to mid-sized freight forwarders. Today, ocean shipping is the
fastest-growing part of Consolidators' business, Keeling says. Those bookings represent 12 percent
of its traffic, more than double the levels at the start of 2009.
Another factor slowing the growth of air freight is the proliferation of sophisticated
forecasting tools that allow businesses to order, ship, warehouse, and distribute with longer lead
times while still meeting their customers' fulfillment requirements. Through better inventory
planning, companies can now divert more shipments to sea freight and use air only for the most
urgent deliveries.
Consider the example of Pacific Sunwear, a maker of trendy apparel geared to the teenage and
young adult markets. The company typically used air freight to ensure that the latest styles were
always in front of its fickle and impatient customer base. However, it has cut its air shipping by
35 percent, according to Alex Albertini, director of logistics and trade compliance.
"We are only moving by air those products that we have a guaranteed sale for without a markdown,"
Albertini told attendees at the eyefortransport third-party logistics summit in June.
A third factor is the mix of fuel-price volatility, tougher security laws, and a general fear of
supply chain disruptions that is pushing businesses to consider nearshoring—a regionalization
of manufacturing and distribution. As the distance shrinks between the various supply chain points,
air freight's value proposition becomes less relevant.
Dell Inc., long a proponent of the intercontinental inventory and shipping model, is "looking
harder at regionalizing our sourcing than we have in the past," said John Lebowitz, director, global
trade management, during a panel discussion following the release of the annual "State of Logistics
Report" in June. Lebowitz added that his company is "doing a much better job" of managing its
manufacturing, inventory, and production flows to take advantage of modes other than air. "We are
definitely looking at diversifying our transportation options," he said.
Will air freight fully recover?
Many fret about globalization and its impact on intercontinental supply chains. But the air-freight
business has proved itself to be a resilient animal, and it's a safe bet that businesses that
continue to scour the globe for low-cost sourcing options will still turn to air to whisk their
goods to far-flung markets.
Some air-freight markets, of course, will do better than others. Traffic in the intra-Asia
region, where production and consumption are expected to remain strong for years to come, will
grow by 8.1 percent annually through 2027, according to Boeing's biennial cargo forecast. That
will significantly outpace the predicted 5.4 percent baseline global growth rate.
Clancy of MergeGlobal says air-freight demand will gradually recover as companies replenish d
epleted inventory and the continued compression of product life cycles drives demand for fast
delivery. He doesn't see the global market returning to 2007 levels—the last full
pre-recession year—until 2012. IATA Chief Economist Brian Pearce, too, says that even if
traffic rebounds along with the global economy, it will take several years to return to the
industry's historical growth rates.
Keeling, though, believes air freight is in "permanent decline." He contends that the
improvement in speed and reliability of competing ocean services will raise the bar to heights that
the air sector can't fly over.
"At one time, if you booked a shipment by ocean originating in St. Louis and bound for
Wellington, New Zealand, the importer would budget 90 days for the cargo to reach its customer,"
he says. "Now you have daily ship calls from Shanghai to Los Angeles, and the all-water transit
times are 12 days. How does air compete with that?"
Robots are revolutionizing factories, warehouses, and distribution centers (DCs) around the world, thanks largely to heavy investments in the technology between 2019 and 2021. And although investment has slowed since then, the long-term outlook calls for steady growth over the next four years. According to data from research and consulting firm Interact Analysis, revenues from shipments of industrial robots are forecast to grow nearly 4% per year, on average, between 2024 and 2028 (see Exhibit 1).
EXHIBIT 1: Market forecast for industrial robots - revenuesInteract Analysis
Material handling is among the top applications for all those robots, accounting for one-third of overall robot market revenues in 2023, according to the research. That puts warehouses and DCs on the cutting edge of robotic innovation, with projects that are helping companies reduce costs, optimize labor, and improve productivity throughout their facilities. Here’s a look at two recent projects that demonstrate the kinds of gains companies have achieved by investing in robotic equipment.
FASTER, MORE ACCURATE CYCLE COUNTS
When leaders at MSI Surfaces wanted to get a better handle on their vast inventory of flooring, countertops, tile, and hardscape materials, they turned to warehouse inventory drone provider Corvus Robotics. The seven-year-old company offers a warehouse drone system, called Corvus One, that can be installed and deployed quickly—in what MSI leaders describe as a “plug and play” process. Corvus Robotics’ drones are fully autonomous—they require no external infrastructure, such as beacons or stickers for positioning and navigation, and no human operators. Essentially, all you need is the drone and a landing pad, and you’re in business.
The drones use computer vision and generative AI (artificial intelligence) to “understand” their environment, flying autonomously in both very narrow aisles—passageways as narrow as 50 inches—and in very wide aisles. The Corvus One system relies on obstacle detection to operate safely in warehouses and uses barcode scanning technology to count inventory; the advanced system can read any barcode symbol in any orientation placed anywhere on the front of a carton or pallet.
The system was the perfect answer to the inventory challenges MSI was facing. Its annual physical inventory counts required two to four dedicated warehouse associates, who would manually scan inventory to determine the amount of stock on hand. The process was both time-consuming and error-prone, and often led to inaccuracies. And it created a chain reaction of issues and problems. Fulfillment speed is one example: Lost or misplaced inventory would delay customer deliveries, resulting in dissatisfaction, returns, and unmet expectations. Productivity was also an issue: Workers were often pulled from fulfillment tasks to locate material, slowing overall operations.
MSI Surfaces began using the Corvus One system in 2021, deploying a small number of drones for daily inventory counts at its 300,000-square-foot distribution center (DC) in Orange, California. It quickly scaled up, adding more drones in Orange and expanding the system to three other DCs: in Houston; Savannah, Georgia; and Edison, New Jersey. The company plans to add more drones to the existing sites and expand the system to some of its smaller DCs as well, according to Corvus Robotics spokesperson Andrew Burer.
Those expansion plans are based on solid results: MSI’s inventory accuracy was about 80% prior to the drone implementation, but it quickly jumped to the high 90s—ultimately reaching 99%—after the company initiated the daily drone counts, according to Burer.
“We actually had an incident early on where one of the forklift drivers ran into the landing pad, rendering it inoperable for about a week while the Corvus team fixed it,” Burer recalls. “When we restarted the system, we noticed MSI’s inventory accuracy had dropped down to the 80s. But after flights resumed, accuracy quickly improved back to near perfect.” He adds that such collisions are rare as Corvus mounts landing pads high off the floor to avoid impacts but that accidents can still happen.
Overall, the system has helped speed warehouse operations in two key ways: First, the accuracy improvement means that associates no longer waste time searching for missing material in the warehouse. And second, the associates who used to conduct the physical inventory counts have been reallocated to picking and replenishment—creating a more efficient, and optimized, workforce.
A SAFER, MORE EFFICIENT WAREHOUSE
Robot maker Boston Dynamics is well-known for its Stretch and Spot industrial robots, both of which are at work in warehouses and DCs around the world. Earlier this year, Stretch made its debut in Europe, teaming up with Spot at a fulfillment center run by German retail company Otto Group. The deployment marks the first time Stretch and Spot are being used together—in a partnership designed to improve Otto Group’s warehousing operations by increasing efficiency and making warehouse work safer and more attractive to workers.
The partnership is part of a two-year project in which Boston Dynamics will deploy dozens of its warehouse robots in Otto Group’s European DCs. The first location is a fulfillment site operated by Hermes, the company’s parcel delivery subsidiary, in Haldensleben, Germany—a facility that handles as many as 40,000 cartons of goods on peak days.
At the site, Stretch—which is a mobile case-handling robot—autonomously unloads ocean containers and trailers, using its advanced perception system to pick and place boxes onto a telescoping conveyor inside the container or trailer. Spot—a quadruped robot—helps with predictive maintenance by collecting thermal data and performing acoustic and visual detection tasks throughout the facility to reduce unplanned downtime and energy costs. One of Spot’s jobs is to detect air leaks in the facility’s warehouse automation systems; future duties may include conveyor vibration detection, according to leaders at Otto Group.
Both Stretch and Spot will help the Haldensleben facility run more efficiently, especially during fall peak season when volume increases and work intensifies. The addition of Stretch addresses safety and comfort issues as well: Trailer unloading—a process that entails repeatedly lifting and moving heavy boxes inside a trailer, which can be dark, dirty, cold, and/or hot, depending on the weather—tends to be unappealing to workers. Along with reducing the amount of labor required, automating these tasks will have the added benefit for European facilities of helping them comply with EU (European Union) regulations limiting the amount of time workers can spend in those conditions.
Essentially, the robots are making life easier on the warehouse floor and for the company at large.
“Stretch is going to have a ton of benefits for customers here in the EU,” Andrew Brueckner, of Boston Dynamics, said in a recent case study on the project.
The trucking industry faces a range of challenges these days, particularly when it comes to load planning—a resource-intensive task that often results in suboptimal decisions, unnecessary empty miles, late deliveries, and inefficient asset utilization. What’s more, delays in decision-making due to a lack of real-time insights can hinder operational efficiency, making cost management a constant struggle.
Truckload carrier Paper Transport Inc. (PTI) experienced this firsthand when the company sought to expand its over the-road (OTR), intermodal, and brokerage offerings to include dedicated fleet services for high-volume shippers—adding a layer of complexity to the business. The additional personnel required for such a move would be extremely costly, leading PTI to investigate technology solutions that could help close the gap.
Enter Freight Science and its intelligent decision-recommendation and automation platform.
PTI implemented Freight Science’s artificial intelligence (AI)-driven load planning optimization solution earlier this year, giving the carrier a high-tech advantage as it launched the new service.
“As PTI tried to diversify … we found that we needed a technological solution that would allow us to process [information] faster,” explains Jared Stedl, chief commercial officer for PTI, emphasizing the high volume of outbound shipments and unique freight characteristics of its targeted dedicated-fleet customers.
The Freight Science platform allowed PTI to apply its signature high-quality service to those needs, all while handling the daily challenges of managing drivers and navigating route disruptions.
STREAMLINING PROCESSES
Dedicated fleets face challenges that evolve from day to day and minute to minute, including truck breakdowns, drivers calling in sick, and rescheduled appointment times. PTI needed a tool that allowed for a real-time view of the fleet, ultimately enabling its team to adjust truck and driver allocation to meet those challenges.
The Freight Science solution filled the bill. The platform uses advanced analytics and algorithms to give carriers better visibility into operations while automating the decision-making process. By combining streaming data, a carrier’s transportation management system (TMS), machine learning, and decision science, the solution allows carriers to deploy their fleets more efficiently while accurately forecasting future needs, according to Freight Science.
In PTI’s case, Freight Science’s software integrates with the carrier’s TMS, real-time electronic logging device (ELD) data, and other external data, feeding an AI model that generates an optimized load plan for the planner.
“We’re an integrated data analytics company for trucking companies,” explains Matt Foster, Freight Science’s president and CEO. “We’re talking about AI.”
The benefits of the real-time data are difficult to overstate.
“We’ve been able to execute in the toughest of situations because we’ve got real, live data on how long each event is actually going to take and a system to aid and even automate the decision-making process,” says Chad Borley, PTI’s operations manager. “From what traffic patterns we are battling in the morning and evening with rush hour and things like that, to the impact of additional miles to a route, or even location-specific dwell times, it’s been a huge differentiator for us.”
REALIZING RESULTS
A case in point: the collapse of Baltimore’s Francis Scott Key Bridge in March. PTI was scheduled to go live with a new dedicated account in the area just days after the collapse, which would mean rerouting and the potential for longer transit times. Instead of recalculating based on assumptions or latent data, PTI was able to reroute freight based on real-time information and analytics to give the customer timely updates.
“With the bridge going out, that changed our ability to make as many turns a day as the customer would expect,” Stedl explains. “But one of the things Freight Science could do [was to] quickly [assess] how much of an impact that traffic would have [and] what the turns [would] be based on what’s happening on the ground.
“So we were able to go back to the customer and readjust expectations in a real way that made sense, using data. Now expectations can be reset¾we’re not asking for forgiveness when there’s no reason for it.”
The system’s advanced algorithms make load planning more cost-effective and scalable as well. The platform allows PTI to monitor trucks, trailers, and driver hours in real time, recommending additional loads with remaining driver hours that would otherwise be wasted.
And they’re doing it all with much less. Stedl says tasks that used to require five people and hours of work can now be accomplished by one person in mere minutes, improving productivity and profitability while reducing labor and operational costs.
Terms of the deal were not disclosed, but Aptean said the move will add new capabilities to its warehouse management and supply chain management offerings for manufacturers, wholesalers, distributors, retailers, and 3PLs. Aptean currently provides enterprise resource planning (ERP), transportation management systems (TMS), and product lifecycle management (PLM) platforms.
Founded in 1980 and headquartered in Durham, U.K., Indigo Software provides software designed for mid-market organizations, giving users real-time visibility and management from the initial receipt of stock all the way through to final dispatch of the finished product. That enables organizations to optimize an array of warehouse operations including receiving, storage, picking, packing, and shipping, the firm says.
Specific sectors served by Indigo Software include the food and beverage, fashion and apparel, fast moving consumer goods, automotive, manufacturing, 3PL, chemicals, and wholesale / distribution verticals.
Online merchants should consider seven key factors about American consumers in order to optimize their sales and operations this holiday season, according to a report from DHL eCommerce.
First, many of the most powerful sales platforms are marketplaces. With nearly universal appeal, 99% of U.S. shoppers buy from marketplaces, ranked in popularity from Amazon (92%) to Walmart (68%), eBay (47%), Temu (32%), Etsy (28%), and Shein (21%).
Second, they use them often, with 61% of American shoppers buying online at least once a week. Among the most popular items are online clothing and footwear (63%), followed by consumer electronics (33%) and health supplements (30%).
Third, delivery is a crucial aspect of making the sale. Fully 94% of U.S. shoppers say delivery options influence where they shop online, and 45% of consumers abandon their baskets if their preferred delivery option is not offered.
That finding meshes with another report released this week, as a white paper from FedEx Corp. and Morning Consult said that 75% of consumers prioritize free shipping over fast shipping. Over half of those surveyed (57%) prioritize free shipping when making an online purchase, even more than finding the best prices (54%). In fact, 81% of shoppers are willing to increase their spending to meet a retailer’s free shipping threshold, FedEx said.
In additional findings from DHL, the Weston, Florida-based company found:
43% of Americans have an online shopping subscription, with pet food subscriptions being particularly popular (44% compared to 25% globally). Social Media Influence:
61% of shoppers use social media for shopping inspiration, and 26% have made a purchase directly on a social platform.
37% of Americans buy from online retailers in other countries, with 70% doing so at least once a month. Of the 49% of Americans who buy from abroad, most shop from China (64%), followed by the U.K. (29%), France (23%), Canada (15%), and Germany (13%).
While 58% of shoppers say sustainability is important, they are not necessarily willing to pay more for sustainable delivery options.
Schneider says its FreightPower platform now offers owner-operators significantly more access to Schneider’s range of freight options. That can help drivers to generate revenue and strengthen their business through: increased access to freight, high drop and hook rates of over 95% of loads, and a trip planning feature that calculates road miles.
“Collaborating with owner-operators is an important component in the success of our business and the reliable service we can provide customers, which is why the network has grown tremendously in the last 25 years,” Schneider Senior Vice President and General Manager of Truckload and Mexico John Bozec said in a release. "We want to invest in tools that support owner-operators in running and growing their businesses. With Schneider FreightPower, they gain access to better load management, increasing their productivity and revenue potential.”