Over the long haul, exports will be the engine that drives the U.S. economy. But without the equipment properly positioned to get the goods from origin to port, the nation's exporters may lose out.
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.
It's the dream of every U.S. politician and globally minded businessman: trillions of dollars of exports pouring into U.S. ports for lading onto ships bound for eager foreign hands.
The dream may be closer to reality than some think. Between 2009 and 2011, the total value of U.S. exports rose at an annualized rate of 15.6 percent, ahead of the 14.9-percent annual growth needed to meet President's Obama's goal (as stated in his 2010 State of the Union address) of doubling export values to about $3.15 trillion by the end of 2014, according to the Commerce Department's International Trade Administration (ITA).
In 2011, U.S. export value hit a record $2.1 trillion and is expected to exceed $2 trillion again in 2012, according to agency data. Export value in March totaled $186.8 billion, a 2.9-percent increase over February totals and an all-time record for any month since numbers have been tracked. Through the first quarter, export value totaled $549.2 billion, an 8.2-percent rise from year-earlier levels.
The beat has continued into 2012, albeit with some recent weakness as the crisis in Europe and slowing of China's growth have cooled U.S. export demand. Growth in export values fell 0.8 percent in April to $182.9 billion, after rising in March to $186.8 billion, which was an all-time record for any month since numbers were kept.
Since 2009, exports have supported the creation of 1.2 million American jobs, the ITA said. The administration's objective is for exports to support 2 million jobs by the end of 2014.
For President Obama, whose stewardship of the economy will likely be the central theme of the upcoming election campaign, the numbers are welcome news, particularly so since his January 2010 clarion call was initially met with skepticism. For example, a survey taken later that year of U.S. high-tech executives found that most believed the goal to be unachievable because it was too costly for companies to manufacture in the United States.
A jaundiced observer might note that the government's data excludes tonnage and shipments, and is skewed toward a metric—values—that is easily influenced by currency fluctuations. A weaker dollar makes U.S. exports less expensive and more competitive in international markets.
In addition, one of the most valuable U.S. exports last year was energy, as much a reflection of rising world oil prices as of the nation's competitiveness.
Still, even when volume figures are put into the data hopper, the outlook for U.S. exports appears bright. William L. Ralph, maritime economist at R.K. Johns & Associates, a New York-based maritime consultancy, said at a conference in Norfolk, Va., in April that he expects containerized U.S. exports to grow 8 to 9 percent this year as strength in Latin American markets—particularly Brazil and Chile—as well as in China offsets weakness in Europe, the destination for 20 percent of containerized goods moving off the East Coast.
Business executives say they are experiencing solid demand from traditional markets outside of Europe. There are also stories about emerging demand for unconventional items from places such as Saudi Arabia, which is importing tens of thousands of containers of water, and Iran, where food producers have a strong need for finished feedstock.
John Fornazor, president of Fornazor International, a New Jersey-based producer and exporter of feeds and grains, said at the Norfolk conference that he sees strong potential in Africa, where arid climates make it difficult for countries to grow their own foodstuffs. "We are very, very high on that part of the world," he said.
John R. Wainwright, head of international trade compliance for Leggett & Platt, a Carthage, Mo.-based manufacturer of residential, commercial, and industrial components, said international consumers' expanding wealth and consumption habits would be a major boon to U.S. exporters. "I am very encouraged about the growing middle class overseas," he told the conference.
WHERE THE BOXES ARE
However, much like the golfer who reaches the green of a par-4 hole in two strokes only to be sabotaged by his putter, all of this enormous export potential could mean nothing without the supply of properly positioned containers to haul the stuff.
Since the early 1990s, the quantities of container equipment—and where they flowed through U.S. commerce—have been pegged to the rapid growth of imports from Asia to the United States. However, the direction of loaded twenty-foot equivalent unit (TEU) container movements across the Pacific is as evenly balanced today as it has been for two decades, according to Walter Kemmsies, New York-based chief economist at Moffatt & Nichol, a global infrastructure adviser.
Each March for the past four years, the United States has come close to net exporting more loaded TEUs than it imported, according to Kemmsies. If the trend persists as Kemmsies expects it will, the United States will become a net exporter of loaded containers during a year's first quarter, while remaining a net importer during the traditional build-up leading into peak season.
But even during the traditionally strong seasonal cycle for imports, the directional imbalances will narrow as fast-growing Asian economies stoke year-round demand for U.S. capital equipment and foodstuffs, among other commodities, Kemmsies said.
Another factor likely to curtail Asian import activity is the growing practice of "near-shoring" production in Mexico and Central America. Near-shoring, designed to bring manufacturing closer to end markets in the United States, reduces demand for Asian-made goods because products can get to their destination in a few days instead of spending weeks on the water.
The trend toward "near-shoring to Mexico is more visible than we know," Kemmsies said.
OFF BALANCE?
The shift in demand patterns threatens to catch the U.S. export infrastructure flat-footed. A supply chain built around containerized imports of retail merchandise unloaded in densely populated commerce centers is often not geographically positioned to transload capital equipment, lumber, and agricultural products that may originate in more remote regions.
In addition, many ship lines calling on West Coast ports are focused on port-to-port business and don't have large-scale commitments with railroads to offer intermodal service to interior U.S. points at competitive rates. Thus, the boxes remain at or near the coast and beyond the reach of exporters.
Ted Prince, who runs a Richmond, Va.-based supply chain consultancy bearing his name, argued the problem isn't the quantity of equipment moving around the country, but the cost of getting boxes to the proper export locations. "There are 'empties' in Dallas and Memphis, but not in Chicago," Prince said. "There's plenty of equipment, but nobody wants to pay to get it in the right place."
Most U.S. exports do not consist of high-value goods because of the relatively high cost of domestic labor that goes into the production; this might explain why IT executives in the November 2010 survey were skeptical about the United States' doubling the value of its exports by the end of 2014. Instead, the nation's exports are predominantly what Prince classifies as "traded commodities," meaning they are of relatively low value and can't command the high per-unit selling prices of high-tech or electronic equipment.
For ocean carriers, it is often too costly to ship empty boxes from the original U.S. import destination to a subsequent export origin just to haul inexpensive commodities to a port. Unless inland shipping costs decline or westbound trans-Pacific rates increase—neither of which is likely for the foreseeable future—"it's just cheaper for the liners to move empty boxes back to the West Coast from their import origin points," Prince said.
"The surplus [of equipment] is in the cities, and the demand is in the hinterlands," said Phillip M. Behanna, senior vice president of International Asset Systems, an Oakland, Calif.-based firm that helps customers reposition containerized equipment.
Henry L. (Rick) Wen Jr., vice president, business development/public affairs for the U.S. arm of liner company Orient Overseas Container Line Inc., echoes that view. "Imports drive the locations where equipment is abundant, and large population centers like Los Angeles and New York-New Jersey have surplus equipment," Wen said in an e-mail. By contrast, exports from the Pacific Northwest and certain Midwest markets currently face equipment deficits, he said.
Since so much export traffic originates from remote locations, Wen said, "cost becomes a factor if carriers are expected to position empty equipment into demand areas for lower-valued cargo." Much of the time, he said, the expense isn't worth the effort.
Behanna of International Asset Systems takes a more optimistic view. He said that, for the first time in years, exporters and ocean carriers are concluding that ridiculously low westbound shipping rates are helping no one. Higher rates will encourage carriers to provide the equipment needed to get exports to the docks, and exporters will be more comfortable knowing that the boxes will be there when they need them, he said.
Behanna said that talk of a container shortage doesn't square with reality, adding that firmer shipping rates for carriers are the tonic needed to correct the imbalance. "If rates go up, the 'shortage' goes away," he said.
To be sure, it is premature to say that export containers are in chronic short supply. Fornazor, head of Fornazor International, said his company has no problem securing containers for its export traffic. Douglas W. Gray, general manager, international transportation operations for Caterpillar Logistics, the logistics arm of titan Caterpillar Inc., said Cat Logistics has contractual agreements that guarantee a specific level of container availability, and that the company's sizable import activity provides a cushion to protect against equipment imbalances.
"We are not generally struggling with getting containers today," Gray said in an e-mail.
Kemmsies, however, believes the future may tell a different tale. Under a scenario where export and import flows are evenly matched, global container positioning will be turned on its head. For years, fully loaded equipment from Asia entered U.S. commerce and would return empty for re-stuffing. In the future, it would not be surprising to see empty containers actually entering the United States from Asia to be filled with exports for the returning westbound move, Kemmsies said.
The worldwide supply chain has not modeled for such a profound change in equipment balance, Kemmsies said. "This then becomes a global logistics problem," he said.
Adding to the positioning issue is the potential of a general shortage of containers to move U.S. exports to their ports-of-departure. Although he doesn't have data to quantify it, Kemmsies said he suspects there will soon be shortages of refrigerated containers as well as twenty-foot containers. In addition, the ratio of container equipment in stock versus equipment in use is today about 2 to 1, down from the traditional 3 to 1 ratio, meaning there are fewer surplus boxes available if they're needed, according to Kemmsies.
"I would rather be a container manufacturer than anyone else right about now," he said. "We are going to need a lot more boxes, or someone is going to have to be real good at equipment positioning."
The New York-based industrial artificial intelligence (AI) provider Augury has raised $75 million for its process optimization tools for manufacturers, in a deal that values the company at more than $1 billion, the firm said today.
According to Augury, its goal is deliver a new generation of AI solutions that provide the accuracy and reliability manufacturers need to make AI a trusted partner in every phase of the manufacturing process.
The “series F” venture capital round was led by Lightrock, with participation from several of Augury’s existing investors; Insight Partners, Eclipse, and Qumra Capital as well as Schneider Electric Ventures and Qualcomm Ventures. In addition to securing the new funding, Augury also said it has added Elan Greenberg as Chief Operating Officer.
“Augury is at the forefront of digitalizing equipment maintenance with AI-driven solutions that enhance cost efficiency, sustainability performance, and energy savings,” Ashish (Ash) Puri, Partner at Lightrock, said in a release. “Their predictive maintenance technology, boasting 99.9% failure detection accuracy and a 5-20x ROI when deployed at scale, significantly reduces downtime and energy consumption for its blue-chip clients globally, offering a compelling value proposition.”
The money supports the firm’s approach of "Hybrid Autonomous Mobile Robotics (Hybrid AMRs)," which integrate the intelligence of "Autonomous Mobile Robots (AMRs)" with the precision and structure of "Automated Guided Vehicles (AGVs)."
According to Anscer, it supports the acceleration to Industry 4.0 by ensuring that its autonomous solutions seamlessly integrate with customers’ existing infrastructures to help transform material handling and warehouse automation.
Leading the new U.S. office will be Mark Messina, who was named this week as Anscer’s Managing Director & CEO, Americas. He has been tasked with leading the firm’s expansion by bringing its automation solutions to industries such as manufacturing, logistics, retail, food & beverage, and third-party logistics (3PL).
Supply chains continue to deal with a growing volume of returns following the holiday peak season, and 2024 was no exception. Recent survey data from product information management technology company Akeneo showed that 65% of shoppers made holiday returns this year, with most reporting that their experience played a large role in their reason for doing so.
The survey—which included information from more than 1,000 U.S. consumers gathered in January—provides insight into the main reasons consumers return products, generational differences in return and online shopping behaviors, and the steadily growing influence that sustainability has on consumers.
Among the results, 62% of consumers said that having more accurate product information upfront would reduce their likelihood of making a return, and 59% said they had made a return specifically because the online product description was misleading or inaccurate.
And when it comes to making those returns, 65% of respondents said they would prefer to return in-store, if possible, followed by 22% who said they prefer to ship products back.
“This indicates that consumers are gravitating toward the most sustainable option by reducing additional shipping,” the survey authors said in a statement announcing the findings, adding that 68% of respondents said they are aware of the environmental impact of returns, and 39% said the environmental impact factors into their decision to make a return or exchange.
The authors also said that investing in the product experience and providing reliable product data can help brands reduce returns, increase loyalty, and provide the best customer experience possible alongside profitability.
When asked what products they return the most, 60% of respondents said clothing items. Sizing issues were the number one reason for those returns (58%) followed by conflicting or lack of customer reviews (35%). In addition, 34% cited misleading product images and 29% pointed to inaccurate product information online as reasons for returning items.
More than 60% of respondents said that having more reliable information would reduce the likelihood of making a return.
“Whether customers are shopping directly from a brand website or on the hundreds of e-commerce marketplaces available today [such as Amazon, Walmart, etc.] the product experience must remain consistent, complete and accurate to instill brand trust and loyalty,” the authors said.
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]."