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.
Depending on one's perspective, FedEx Corp.'s planned Jan. 1 switch to dimensional pricing on ground parcel shipments
measuring less than three cubic feet is either another attempt to grab shippers by the short hairs or a rational move to
price its surface capacity in line with an evolving traffic mix. The policy change could also wean customers off an addiction
to excess packaging that adds unnecessary cube and cost to each delivery.
Because the announcement is only 10 days old, the debate is just taking shape. Yet two points are clear: The move is
unprecedented—as of Jan. 1 all FedEx ground shipments will be priced based on their dimensions instead of their weight.
But though the move is unprecedented, the objective isn't. Memphis-based FedEx and its chief rival, Atlanta-based UPS Inc.,
have tried for seven years to convince shippers to either tighten up their packaging or to fit more weight within the parcels
they tender.
Since 2007, both have used the tool of volumetric division, where a parcel's cube is divided by a preset divisor, to price
packages based not on their weight but on how much space they occupy on a delivery van. In January 2011, both shrunk their
divisors to 166 from 194 to make it even costlier to tender lightweight, bulky parcels that take up a disproportionate share of
van capacity and, according to the carriers, distort their pricing. Currently, however, shipments under the three cubic-feet
threshold are exempt. As a result, a 5-pound parcel measuring less than three cubic feet is priced based on its weight.
FedEx's move changes the game. Take, for example, a one cubic foot box that measures 1,728 cubic inches, the sum of multiplying
the shipment's height, weight, and length. Dividing that number by the divisor of 166 now in effect yields dimensional pricing of
about 11 pounds, even if the parcel weighs less than that.
Extending the math to the three cubic-feet threshold only amplifies the magnitude of the change: Dividing 5,184 cubic inches by
the 166 divisor yields a rate equal to that of a 36-pound shipment. Shippers generally pay the greater of the actual or dimensional
weight.
To put it in ways a layperson could understand, come Jan. 1, a package of toilet paper ordered on Amazon.com that weighs 5
pounds could be priced as if it was a 20-pound shipment.
SHEDDING B2C WEIGHT?
Those affected by the shift have several choices: add heft to their packages so they can be priced by the weight, reduce
the cubic dimensions of the parcels through more efficient packaging, pay the higher charges, minimize the damage through
effective negotiation, or go elsewhere. Some choices are considered feasible. Others appear less so.
However, it is the last option that FedEx may have had in mind when developing its strategy. The explosive growth of
e-commerce has pushed more business-to-consumer (B2C) shipments into FedEx's ground network than ever before. Most of those
shipments consist of lightweight, bulky items. What's more, an e-commerce transaction often involves the delivery of only one
item. By contrast, a typical business-to-business (B2B) delivery stop comprises multiple packages each weighing a decent amount,
a more profitable scenario for a carrier.
Given that carriers price their delivery expenses on a per-stop basis, it isn't surprising B2C shipments have become an
exercise in margin compression. The problem is amplified by a shipper's insistence to surround the product with Styrofoam popcorn,
Bubble Wrap, or other types of padding that may or may not add protection but certainly add to cube. Jaris Briski, general manager
of integrated parcel solutions for Pittsburgh-based third party logistics provider Genco, said he's concluded from numerous visits
to shippers' facilities that "they are very generous" with additional packaging and that the FedEx move will force many to "take a
serious look at their configurations."
The low-margin nature of B2C deliveries drove FedEx and UPS several years ago to partner with the U.S. Postal Service (USPS) to
use the USPS' low-cost, universal delivery network to bring parcels mostly to residential destinations. (The FedEx-USPS alliance,
known as "SmartPost," is exempt from the pricing change.) It could also explain why the FedEx move is aimed largely at the 1- to
10-pound weight range where e-commerce lives. Most B2C shipments weigh 5 pounds or less.
Rick Jones, president and CEO of Austin, Texas-based LSO (formerly Lone Star Overnight), a regional parcel carrier, reckons
that FedEx wants to recalibrate its traffic mix so B2B shipments comprise more of its density. This, in turn, may lead to a
shedding of B2C business as merchants that lack the volume leverage of a company like Amazon.com are effectively priced out of
the FedEx system, he said.
Jones, who spent 22 years at UPS, said his old employer would likely follow FedEx's lead because it faces the same predicament.
UPS has said it is studying the FedEx decision, but declined further comment.
It is difficult to quantify the volume of shipments that could be affected by the FedEx change, and the estimates get murkier
if UPS, which handles three times the daily ground volumes, is thrown into the mix. According to consulting company SJ Consulting,
which maintains a database of 100 million domestic parcels moved annually, 32 percent of that number have shipment characteristics
that would make them vulnerable to the FedEx move. Within that subset, about 57 percent of shipments weigh 5 pounds or less, weight
breaks that would face the steepest increase, according to Satish Jindel, SJ's president.
Jindel said his database may understate the impact, however. FedEx and UPS combined handle about 16 million ground parcels each
shipping day. When that number is multiplied by 250 or so shipping days, the volume of affected packages "can go much higher" than
the universe his company tracks, Jindel said. The change will add an estimated $186 million to FedEx's annual operating income
without its FedEx Ground unit doing anything to change its operations, he forecast.
RATIONAL BEHAVIOR
Jindel said pundits who claim FedEx's actions smack of price gouging have little clue about the cost structure of its ground
business. As more e-commerce flows into the system, the traffic mix will get lighter and bulkier. This will require the company
to spend more on various types of equipment, notably larger delivery vans. Add to that the cube-busting bloat of extra packaging,
and it is easy to see why FedEx believes it has no choice but to be properly compensated for carrying parcels that don't pay their
way.
"This is not exploitation," he said. "This is a company that is adjusting to profound changes in its business."
Over the next seven months, many FedEx customers will have key decisions to make. Much depends on the course UPS takes.
Presuming UPS follows suit, they can turn to the Postal Service, which does not employ dimensional pricing. However, USPS may
not be able to handle an avalanche of new B2C business without increased capital investment in plant, facilities, and equipment,
moves that could force it to take significant rate increases of its own.
Customers could also turn to the regional parcel carriers. Mark Magill, vice president of business development for Chandler,
Ariz.-based OnTrac, a regional carrier that serves eight western states including all of California, said his company employs a
more shipper-friendly volumetric divisor of 194. Magill said he uses that as a selling point, adding that he will go even higher
if the customer is large enough. Jones of LSO, which uses the same divisor of 166 as FedEx and UPS, said the regionals could
exempt shipments measuring one to two cubic feet from dimensional pricing; this would give a break to the many e-commerce
shipments that cube out at such micro levels.
Customers could bargain for exemptions. Briski of Genco, which helps customers negotiate with the carriers, said he's begun
advising clients on ways to leverage their contractual volumes to minimize the impact of the pricing change. It will be virtually
impossible, however, to eliminate the impact, he said.
The next step, Briski said, will be to work with clients to modify their packaging. For decades, packaging sizes were basically
uniform. The result was a lot of empty air that ended up being filled with useless stuff. But the world has changed. Today,
packaging comes in all shapes and sizes. What's more, it can be customized, almost on the fly, to meet a shipper's individual
needs.
As with so many circumstances, one person's misery is another's opportunity. "It's a good time to be in the packaging
engineering business," said Jones of LSO.
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.