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?"
When you get the chance to automate your distribution center, take it.
That's exactly what leaders at interior design house
Thibaut Design did when they relocated operations from two New Jersey distribution centers (DCs) into a single facility in Charlotte, North Carolina, in 2019. Moving to an "empty shell of a building," as Thibaut's Michael Fechter describes it, was the perfect time to switch from a manual picking system to an automated one—in this case, one that would be driven by voice-directed technology.
"We were 100% paper-based picking in New Jersey," Fechter, the company's vice president of distribution and technology, explained in a
case study published by Voxware last year. "We knew there was a need for automation, and when we moved to Charlotte, we wanted to implement that technology."
Fechter cites Voxware's promise of simple and easy integration, configuration, use, and training as some of the key reasons Thibaut's leaders chose the system. Since implementing the voice technology, the company has streamlined its fulfillment process and can onboard and cross-train warehouse employees in a fraction of the time it used to take back in New Jersey.
And the results speak for themselves.
"We've seen incredible gains [from a] productivity standpoint," Fechter reports. "A 50% increase from pre-implementation to today."
THE NEED FOR SPEED
Thibaut was founded in 1886 and is the oldest operating wallpaper company in the United States, according to Fechter. The company works with a global network of designers, shipping samples of wallpaper and fabrics around the world.
For the design house's warehouse associates, picking, packing, and shipping thousands of samples every day was a cumbersome, labor-intensive process—and one that was prone to inaccuracy. With its paper-based picking system, mispicks were common—Fechter cites a 2% to 5% mispick rate—which necessitated stationing an extra associate at each pack station to check that orders were accurate before they left the facility.
All that has changed since implementing Voxware's Voice Management Suite (VMS) at the Charlotte DC. The system automates the workflow and guides associates through the picking process via a headset, using voice commands. The hands-free, eyes-free solution allows workers to focus on locating and selecting the right item, with no paper-based lists to check or written instructions to follow.
Thibaut also uses the tech provider's analytics tool, VoxPilot, to monitor work progress, check orders, and keep track of incoming work—managers can see what orders are open, what's in process, and what's completed for the day, for example. And it uses VoxTempo, the system's natural language voice recognition (NLVR) solution, to streamline training. The intuitive app whittles training time down to minutes and gets associates up and working fast—and Thibaut hitting minimum productivity targets within hours, according to Fechter.
EXPECTED RESULTS REALIZED
Key benefits of the project include a reduction in mispicks—which have dropped to zero—and the elimination of those extra quality-control measures Thibaut needed in the New Jersey DCs.
"We've gotten to the point where we don't even measure mispicks today—because there are none," Fechter said in the case study. "Having an extra person at a pack station to [check] every order before we pack [it]—that's been eliminated. Not only is the pick right the first time, but [the order] also gets packed and shipped faster than ever before."
The system has increased inventory accuracy as well. According to Fechter, it's now "well over 99.9%."
IT projects can be daunting, especially when the project involves upgrading a warehouse management system (WMS) to support an expansive network of warehousing and logistics facilities. Global third-party logistics service provider (3PL) CJ Logistics experienced this first-hand recently, embarking on a WMS selection process that would both upgrade performance and enhance security for its U.S. business network.
The company was operating on three different platforms across more than 35 warehouse facilities and wanted to pare that down to help standardize operations, optimize costs, and make it easier to scale the business, according to CIO Sean Moore.
Moore and his team started the WMS selection process in late 2023, working with supply chain consulting firm Alpine Supply Chain Solutions to identify challenges, needs, and goals, and then to select and implement the new WMS. Roughly a year later, the 3PL was up and running on a system from Körber Supply Chain—and planning for growth.
SECURING A NEW SOLUTION
Leaders from both companies explain that a robust WMS is crucial for a 3PL's success, as it acts as a centralized platform that allows seamless coordination of activities such as inventory management, order fulfillment, and transportation planning. The right solution allows the company to optimize warehouse operations by automating tasks, managing inventory levels, and ensuring efficient space utilization while helping to boost order processing volumes, reduce errors, and cut operational costs.
CJ Logistics had another key criterion: ensuring data security for its wide and varied array of clients, many of whom rely on the 3PL to fill e-commerce orders for consumers. Those clients wanted assurance that consumers' personally identifying information—including names, addresses, and phone numbers—was protected against cybersecurity breeches when flowing through the 3PL's system. For CJ Logistics, that meant finding a WMS provider whose software was certified to the appropriate security standards.
"That's becoming [an assurance] that our customers want to see," Moore explains, adding that many customers wanted to know that CJ Logistics' systems were SOC 2 compliant, meaning they had met a standard developed by the American Institute of CPAs for protecting sensitive customer data from unauthorized access, security incidents, and other vulnerabilities. "Everybody wants that level of security. So you want to make sure the system is secure … and not susceptible to ransomware.
"It was a critical requirement for us."
That security requirement was a key consideration during all phases of the WMS selection process, according to Michael Wohlwend, managing principal at Alpine Supply Chain Solutions.
"It was in the RFP [request for proposal], then in demo, [and] then once we got to the vendor of choice, we had a deep-dive discovery call to understand what [security] they have in place and their plan moving forward," he explains.
Ultimately, CJ Logistics implemented Körber's Warehouse Advantage, a cloud-based system designed for multiclient operations that supports all of the 3PL's needs, including its security requirements.
GOING LIVE
When it came time to implement the software, Moore and his team chose to start with a brand-new cold chain facility that the 3PL was building in Gainesville, Georgia. The 270,000-square-foot facility opened this past November and immediately went live running on the Körber WMS.
Moore and Wohlwend explain that both the nature of the cold chain business and the greenfield construction made the facility the perfect place to launch the new software: CJ Logistics would be adding customers at a staggered rate, expanding its cold storage presence in the Southeast and capitalizing on the location's proximity to major highways and railways. The facility is also adjacent to the future Northeast Georgia Inland Port, which will provide a direct link to the Port of Savannah.
"We signed a 15-year lease for the building," Moore says. "When you sign a long-term lease … you want your future-state software in place. That was one of the key [reasons] we started there.
"Also, this facility was going to bring on one customer after another at a metered rate. So [there was] some risk reduction as well."
Wohlwend adds: "The facility plus risk reduction plus the new business [element]—all made it a good starting point."
The early benefits of the WMS include ease of use and easy onboarding of clients, according to Moore, who says the plan is to convert additional CJ Logistics facilities to the new system in 2025.
"The software is very easy to use … our employees are saying they really like the user interface and that you can find information very easily," Moore says, touting the partnership with Alpine and Körber as key to making the project a success. "We are on deck to add at least four facilities at a minimum [this year]."
First, 54% of retailers are looking for ways to increase their financial recovery from returns. That’s because the cost to return a purchase averages 27% of the purchase price, which erases as much as 50% of the sales margin. But consumers have their own interests in mind: 76% of shoppers admit they’ve embellished or exaggerated the return reason to avoid a fee, a 39% increase from 2023 to 204.
Second, return experiences matter to consumers. A whopping 80% of shoppers stopped shopping at a retailer because of changes to the return policy—a 34% increase YoY.
Third, returns fraud and abuse is top-of-mind-for retailers, with wardrobing rising 38% in 2024. In fact, over two thirds (69%) of shoppers admit to wardrobing, which is the practice of buying an item for a specific reason or event and returning it after use. Shoppers also practice bracketing, or purchasing an item in a variety of colors or sizes and then returning all the unwanted options.
Fourth, returns come with a steep cost in terms of sustainability, with returns amounting to 8.4 billion pounds of landfill waste in 2023 alone.
“As returns have become an integral part of the shopper experience, retailers must balance meeting sky-high expectations with rising costs, environmental impact, and fraudulent behaviors,” Amena Ali, CEO of Optoro, said in the firm’s “2024 Returns Unwrapped” report. “By understanding shoppers’ behaviors and preferences around returns, retailers can create returns experiences that embrace their needs while driving deeper loyalty and protecting their bottom line.”
Facing an evolving supply chain landscape in 2025, companies are being forced to rethink their distribution strategies to cope with challenges like rising cost pressures, persistent labor shortages, and the complexities of managing SKU proliferation.
1. Optimize labor productivity and costs. Forward-thinking businesses are leveraging technology to get more done with fewer resources through approaches like slotting optimization, automation and robotics, and inventory visibility.
2. Maximize capacity with smart solutions. With e-commerce volumes rising, facilities need to handle more SKUs and orders without expanding their physical footprint. That can be achieved through high-density storage and dynamic throughput.
3. Streamline returns management. Returns are a growing challenge, thanks to the continued growth of e-commerce and the consumer practice of bracketing. Businesses can handle that with smarter reverse logistics processes like automated returns processing and reverse logistics visibility.
4. Accelerate order fulfillment with robotics. Robotic solutions are transforming the way orders are fulfilled, helping businesses meet customer expectations faster and more accurately than ever before by using autonomous mobile robots (AMRs and robotic picking.
5. Enhance end-of-line packaging. The final step in the supply chain is often the most visible to customers. So optimizing packaging processes can reduce costs, improve efficiency, and support sustainability goals through automated packaging systems and sustainability initiatives.
Keith Moore is CEO of AutoScheduler.AI, a warehouse resource planning and optimization platform that integrates with a customer's warehouse management system to orchestrate and optimize all activities at the site. Prior to venturing into the supply chain business, Moore was a director of product management at software startup SparkCognition. He is a graduate of the University of Tennessee, where he earned a Bachelor of Science degree in mechanical engineering.
Q: Autoscheduler provides tools for warehouse orchestration—a term some readers may not be familiar with. Could you explain what warehouse orchestration means?
A: Warehouse orchestration tools are software control layers that synthesize data from existing systems to eliminate costly delays, streamline inefficient workflows, and [prevent the waste of] resources in distribution operations. These platforms empower warehouses to optimize operations, enhance productivity, and improve order accuracy by dynamically prioritizing work continuously to ensure that the operation is always running optimally. This leads to faster trailer turn times, reduced costs, and a network that runs like clockwork, even during fluctuating demands.
Q: How is orchestration different from a typical warehouse management system?
A: A warehouse management system (WMS) focuses on tracking inventory and managing warehouse operations. Warehouse orchestration goes a step further by integrating and optimizing all aspects of warehouse activities in a capacity-constrained way. Orchestration provides a dynamic, real-time layer that coordinates various systems and processes, enabling more agile and responsive operations. It enhances decision-making by considering multiple variables and constraints.
Q: How does warehouse orchestration help facilities make their workers more productive?
A: Two ways to make labor in a warehouse more productive are to work harder and to work smarter. For teams that want to work harder, most companies use a labor management system to track individual performances against an expected standard. Warehouse orchestration technology focuses on the other side of the coin, helping warehouses "work smarter."
Warehouse orchestration technology optimizes labor by providing real-time insights into workload demands and resource availability based on actual fluctuating constraints around the building. It enables dynamic task assignments based on current priorities and worker skills, ensuring that labor is allocated where it's needed most, even accounting for equipment availability, flow constraints, and overall work speed. This approach reduces idle time, balances workloads, and enhances employee productivity.
Q: How can visibility improve operations?
A: Due to the software ecosystem in place today, most distribution operations are highly reactive environments where there is always a "hair on fire" problem that needs to be solved. By leveraging orchestration technologies, this problem is mitigated because you're providing the site with added visibility into the past, present, and future state of the operation. This opens up a vast number of doors for distribution leadership. They go from learning about a problem after it's happened to gaining the ability to inform customers and transportation teams about potential service issues that are 24 hours away.