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.
One thing that can be said about the supply chain: It is a Petri dish for new ideas, even if many of them end up being unworkable in practice.
Take the notion that a group of regional carriers could cobble together a third national network to fill the void left by DHL Express when it exited the U.S. market in January 2009. Few question the need for more parcel competition, especially as FedEx Corp. and UPS Inc., who dominate the U.S. parcel business, continue to raise rates, and add or increase accessorial charges, seemingly in lockstep.
In addition, the creation in 2008 of the "Reliance Network," a group of eight regional truckers in the U.S. and Canada that joined forces to build a nationwide infrastructure, has shown that a national model built around the amalgamation of regional carriers can gain acceptance with shippers.
Yet in the parcel world, which is a different kind of transport animal, the reality is that a third national network similar to what DHL attempted is unlikely to materialize. Beyond the cost of replicating a model that took FedEx and UPS many years and billions of dollars to build, each of the largest regional carriers has its own operating schemes, customer targets, and pricing matrixes, which would be difficult to integrate on a national scale.
The technologies are also disparate, though there has been progress to develop an IT backbone to support a unified infrastructure. One Network Enterprises, a Dallas-based IT provider, has created the "Real Time Value Network," which One Network says gives 30,000 parcel users across the U.S. real-time visibility of the shipment cycle from order placement, to proof of delivery, to reporting, online billing, and payment options. Last September, Greyhound Package Express, the parcel unit of the legendary intercity bus operator Greyhound Lines Inc., joined the network to link its depots with local parcel haulers.
But harmonized technology may be the least of the roadblocks. A September survey of 17 large regional carriers by Shipware LLC, a San Diego-based parcel consultancy, found that only 17 percent believed a unified IT network was the greatest challenge to creating a nationwide infrastructure. By contrast, 50 percent said the main impediment was developing a fair system for carriers to share their revenue on interline moves. About 33 percent said the primary challenge lies with the ability to merge different specializations, equipment, and service standards.
According to Rob Martinez, CEO of Shipware, regional alliances work best when they involve contracted rates based on the number of stops a driver makes, rather than the number of packages carried. "The ideal customer has multiple pieces going to a single destination," said Martinez, adding that delivery density is the key element in executing a profitable venture.
Building package density is easier said than done. In fact, Rick Jones, CEO of Lone Star Overnight, an Austin, Texas-based carrier that serves Texas, Oklahoma, western Louisiana, and southern New Mexico, and through an alliance with Mexican carrier Estafeta reaches all of Mexico, said the lack of density is probably the biggest reason why a national network would not succeed. Even DHL Express, a major carrier by any measure, failed to achieve sufficient density in the U.S. to compete profitably against FedEx and UPS, Jones said. According to unscientific estimates, UPS alone carries as many packages and letters in two business days—about 32 to 33 million pieces worldwide—as the largest regional carrier moves in a year.
Jones said strategic alliances can broaden a regional carrier's reach without the inherent complexities of a revenue-sharing agreement. Six months ago, Lone Star began a venture with OnTrac, a regional carrier serving eight western states, including all of California. Under the venture, called "LSO Plus," Lone Star loads a 53-foot tractor-trailer in Austin and brings it to On-Trac's Phoenix facility. There, some of its customers' packages are inducted into OnTrac's system to be locally distributed. The truck then rolls on to OnTrac's main distribution center in Commerce, Calif., just east of Los Angeles, where the rest of the packages, which are bound for West Coast markets, are fed into OnTrac's system for delivery.
Lone Star bills its customer for the through move and pays OnTrac for the regional distribution. Lone Star is the customer's main point of contact. All surcharges associated with the service are the same between the two carriers, minimizing any chance of customer confusion, Jones said.
OnTrac does not currently ship into Lone Star's territory, mainly because it is too costly for the venture, which has yet to turn a profit, to run a 53-foot tractor-trailer from California to Texas, Jones said. Lone Star has enough faith in the model to seriously consider expanding it into the Midwest, the most logical adjacent geography for the company, Jones said.
E-COMMERCE'S IMPACT
Yet the need for a national parcel system may be mooted by a force of nature called e-commerce. Most e-commerce shipments move between 300 and 500 miles, which mirror the average length of haul in most domestic truck commerce. The distance fits smartly within a regional carrier's territory. In addition, because regional carriers serve a limited geography, they can focus their resources on offering later cutoff times and still make next-day ground deliveries within a 400-mile radius, something FedEx and UPS generally don't do. This is a boon for online retailers whose "stores" are open 24/7 and who must placate impatient consumers and businesses that want their products yesterday.
The growth of e-commerce could make the regional carrier world an interesting place by mid-decade. As e-merchants expand their fulfillment locations to shorten delivery times, they will also need to enlarge their transportation footprint. They could continue to buy transportation, or become vertically integrated by acquiring a regional carrier or two. It wouldn't take much capital for the likes of Wal-Mart Stores, Target Stores, Amazon.com, and e-Bay to snap up a regional player to have a closed-loop distribution network.
Foreign companies who lack an e-commerce presence in the United States may find regional players appetizing targets. FedEx and UPS, tired of watching the regionals siphon off volumes in a fast-growing segment, may buy out some of the players just to take them off their field. Even truckload and LTL carriers could enter the buying fray to round out their product portfolios.
Then there is the chance none of the above occurs and the industry morphs through a series of alliances into two or three "super-regionals" forming a de facto national network. One company that may be positioned to grab the baton is Pitt-Ohio, a Pittsburgh-based regional LTL and truckload carrier that three years ago entered the ground parcel business. Privately held Pitt-Ohio is cash-rich and has experience with a super-regional infrastructure as one of the partners in the "Reliance Network." In 2011, it acquired US Cargo, a Columbus, Ohio-based parcel carrier serving eight states in the Midwest, Ohio Valley, mid-Atlantic, and Northeast. US Cargo, which still operates independently, has an interline relationship with Eastern Connection, a Massachusetts-based regional carrier whose network stretches from Maine to Virginia.
Pitt-Ohio wants to expand its ground parcel operations, which began as an adjunct to its core offerings. It already interchanges tracking and billing data with OnTrac, US Cargo, Eastern Connection, and other parcel carriers, according to Kent Szalla, general manager of its ground division. It develops revenue-sharing arrangements with other carriers on a case-by-case basis, he said.
Pitt-Ohio rolled out the parcel service on a limited scale, initially selling it only to current customers or shippers who've done business with the carrier before. At the time, Szalla said it was building the parcel product piece by piece. Three years later, the company still seems to be in no rush to blast it out to the marketplace.
"Our mantra is crawl, walk, and then run," Szalla said in an e-mail. "We already began to crawl by bringing on opportunities that fit. Walking, and then running, will take some time."
Agility Robotics, the small Oregon company that makes walking robots for warehouse applications, has taken on new funding from the powerhouse German automotive and industrial parts supplier Schaeffler AG, the firm said today.
Terms of the deal were not disclosed, but Schaeffler has made “a minority investment” in Agility and signed an agreement to purchase its humanoid robots for use across the global Schaeffler plant network.
That newly combined entity will generate annual revenue of around $26 billion, employ a workforce of some 120,000, and serve its customers from more than 44 research & development (R&D centers and more than 100 production sites around the world. The new setup will include four business divisions: E-Mobility, Powertrain & Chassis, Vehicle Lifetime Solutions and Bearings & Industrial Solutions.
“In disruptive times, implementing innovative manufacturing solutions is crucial to be successful. Here, humanoids play an important role,” Andreas Schick, Chief Operating Officer of Schaeffler AG, said in a release. “We, at Schaeffler, will integrate this technology into our operations and see the potential to deploy a significant number of humanoids in our global network of 100 plants by 2030. We look forward to the collaboration with Agility Robotics which will accelerate our activities in this field.”
Agility makes the “Digit” product, which it calls a bipedal Mobile Manipulation Robot (MMR). Earlier this year, Agility also began deploying its humanoid robots through a multi-year agreement with contract logistics provider GXO.
The Boston-based enterprise software vendor Board has acquired the California company Prevedere, a provider of predictive planning technology, saying the move will integrate internal performance metrics with external economic intelligence.
According to Board, the combined technologies will integrate millions of external data points—ranging from macroeconomic indicators to AI-driven predictive models—to help companies build predictive models for critical planning needs, cutting costs by reducing inventory excess and optimizing logistics in response to global trade dynamics.
That is particularly valuable in today’s rapidly changing markets, where companies face evolving customer preferences and economic shifts, the company said. “Our customers spend significant time analyzing internal data but often lack visibility into how external factors might impact their planning,” Jeff Casale, CEO of Board, said in a release. “By integrating Prevedere, we eliminate those blind spots, equipping executives with a complete view of their operating environment. This empowers them to respond dynamically to market changes and make informed decisions that drive competitive advantage.”
Material handling automation provider Vecna Robotics today named Karl Iagnemma as its new CEO and announced $14.5 million in additional funding from existing investors, the Waltham, Massachusetts firm said.
The fresh funding is earmarked to accelerate technology and product enhancements to address the automation needs of operators in automotive, general manufacturing, and high-volume warehousing.
Iagnemma comes to the company after roles as an MIT researcher and inventor, and with leadership titles including co-founder and CEO of autonomous vehicle technology company nuTonomy. The tier 1 supplier Aptiv acquired Aptiv in 2017 for $450 million, and named Iagnemma as founding CEO of Motional, its $4 billion robotaxi joint venture with automaker Hyundai Motor Group.
“Automation in logistics today is similar to the current state of robotaxis, in that there is a massive market opportunity but little market penetration,” Iagnemma said in a release. “I join Vecna Robotics at an inflection point in the material handling market, where operators are poised to adopt automation at scale. Vecna is uniquely positioned to shape the market with state-of-the-art technology and products that are easy to purchase, deploy, and operate reliably across many different workflows.”
In a push to automate manufacturing processes, businesses around the world have turned to robots—the latest figures from the Germany-based International Federation of Robotics (IFR) indicate that there are now 4,281,585 robot units operating in factories worldwide, a 10% jump over the previous year. And the pace of robotic adoption isn’t slowing: Annual installations in 2023 exceeded half a million units for the third consecutive year, the IFR said in its “World Robotics 2024 Report.”
As for where those robotic adoptions took place, the IFR says 70% of all newly deployed robots in 2023 were installed in Asia (with China alone accounting for over half of all global installations), 17% in Europe, and 10% in the Americas. Here’s a look at the numbers for several countries profiled in the report (along with the percentage change from 2022).
Sean Webb’s background is in finance, not package engineering, but he sees that as a plus—particularly when it comes to explaining the financial benefits of automated packaging to clients. Webb is currently vice president of national accounts at Sparck Technologies, a company that manufactures automated solutions that produce right-sized packaging, where he is responsible for the sales and operational teams. Prior to joining Sparck, he worked in the financial sector for PEAK6, E*Trade, and ATD, including experience as an equity trader.
Webb holds a bachelor’s degree from Michigan State and an MBA in finance from Western Michigan University.
Q: How would you describe the current state of the packaging industry?
A: The packaging and e-commerce industries are rapidly evolving, driven by shifting consumer preferences, technological advancements, and a heightened focus on sustainability. The packaging sector is increasingly prioritizing eco-friendly materials to reduce waste, while integrating smart technologies and customizable solutions to enhance brand engagement.
The e-commerce industry continues to expand, fueled by the convenience of online shopping and accelerated by the pandemic. Advances in artificial intelligence and augmented reality are enhancing the online shopping experience, while consumer expectations for fast delivery and seamless transactions are reshaping logistics and operations.
In addition, with the growth in environmental and sustainability regulatory initiatives—like Extended Producer Responsibility (EPR) laws and a New Jersey bill that would require retailers to use right-sized shipping boxes—right-sized packaging is playing a crucial role in reducing packaging waste and box volume.
Q: You came from the financial and equity markets. How has that been an advantage in your work as an executive at Sparck?
A: My background has allowed me to effectively communicate the incredible ROI [return on investment] and value that right-size automated packaging provides in a way that financial teams understand. Investment in this technology provides significant labor, transportation, and material savings that typically deliver a positive ROI in six to 18 months.
Q: What are the advantages to using automated right-sized packaging equipment?
A: By automating the packaging process to create right-sized boxes, facilities can boost productivity by streamlining operations and reducing manual handling. This leads to greater operational efficiency as automated systems handle tasks with precision and speed, minimizing downtime.
The use of right-sized packaging also results in substantial labor savings, as less labor is required for packaging tasks. In addition, these systems support scalability, allowing facilities to easily adapt to increased order volumes and evolving needs without compromising performance.
Q: How can automation help ease the labor problems associated with time-consuming pack-out operations?
A: Not only has the cost of labor increased dramatically, but finding a consistent labor force to keep up with the constant fluctuations around peak seasons is very challenging. Typically, one manual laborer can pack at a rate of 20 to 35 packages per hour. Our CVP automated packaging solution can pack up to 1,100 orders per hour utilizing a fully integrated system. This system not only creates a right-sized box, but also accurately weighs it, captures its dimensions, and adds the necessary carrier information.
Q: Beyond material savings, are there other advantages for transportation and warehouse functions in using right-sized packaging?
A: Yes. By creating smaller boxes, right-sizing enables more parcels to fit on a truck, leading to significant shipping and transportation savings. This also results in reduced CO2 emissions, as fewer truckloads are required. In addition, parcels with right-sized packaging are less prone to damage, and automation helps minimize errors.
In a warehouse setting, smaller packages are easier to convey and sort. Using a fully integrated system that combines multiple functions into a smaller footprint can also lead to operational space savings.
Q: Can you share any details on the typical ROI and the savings associated with packaging automation?
A: Three-dimensional right-sized packaging automation boosts productivity significantly, leading to increased overall revenue. Labor savings average 88%, and transportation savings accrue with each right-sized box. In addition, material savings from less wasteful use of corrugated packaging enhance the return on investment for companies. Together, these typically deliver returns in under 18 months, with some projects achieving ROI in as little as six months. These savings can total millions of dollars for businesses.
Q: How can facility managers convince corporate executives that automated packaging technology is a good investment for their operation?
A: We like to take a data-driven approach and utilize the actual data from the customer to understand the right fit. Using those results, we utilize our ROI tool to accurately project the savings, ROI, IRR (internal rate of return), and NPV (net present value) that facility managers can then use to [elicit] the support needed to make a good investment for their operation.
Q: Could you talk a little about the enhancements you’ve recently made to your automated solutions?
A: Sparck has introduced a number of enhancements to its packaging solutions, including fluting corrugate that supports packages of various weights and sizes, allowing the production of ultra-slim boxes with a minimum height of 28mm (1.1 inches). This innovation revolutionizes e-commerce packaging by enabling smaller parcels to fit through most European mailboxes, optimizing space in transit and increasing throughput rates for automated orders.
In addition, Sparck’s new real-time data monitoring tools provide detailed machine performance insights through various software solutions, allowing businesses to manage and optimize their packaging operations. These developments offer significant delivery performance improvements and cost savings globally.