USPS, rivals and mailers knock heads over alleged cross-subsidy of products
First-class mail may be subsidizing expansion of shipping services, rivals say; USPS denies claims, says costing data follows Postal Commission guidelines.
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.
Ever since Congress changed the rules of the U.S. Postal Service's game nearly a decade ago, USPS' rivals and some of its larger customers have raised concerns over whether it subsidizes fast-growing delivery products that compete in an open market with proceeds from flagging monopolies such as first-class mail that have been hammered by digital conversion. The debate has recently flared anew. This time, it surfaces at a critical juncture for USPS as well as for companies involved in postal commerce.
Over the past 45 days, several parties have asked the Postal Regulatory Commission, the agency that oversees USPS' operations, to take a deep dive into how the Postal Service accounts for costs across its product lines. The question, according to entities ranging from Atlanta-based UPS Inc. and Memphis-based FedEx Corp. to the Association for Postal Commerce, a group composed of large mailers, is whether USPS provides enough information about its costs to prove the quasigovernmental agency is covering each product's expenses from its corresponding revenue stream, or if it is, in effect, "robbing Peter to pay Paul." By law, USPS provides costing data in its annual compliance review, submitted to the postal commission.
For UPS and FedEx, which compete and collaborate with the Postal Service, the concern centers on whether USPS shifts funds from so-called "market dominant" products such as first-class mail to support the expansion of expedited delivery services like Priority Mail and Parcel Select. Both services allow businesses consolidating large parcel volumes to induct them deep into the postal system for final deliveries, mostly to residences. The services are labeled "competitive products" because they compete with private-sector companies, although Parcel Select has become a de facto monopoly because it levers USPS' unmatched delivery network (by law, it delivers to every U.S. address) and is priced at levels no other provider can touch. UPS and FedEx, for example, use Parcel Select to provide "last-mile" parcel deliveries to mostly residential areas that lack the customer density for either company to serve efficiently on their own.
The dispute has its roots in a 2006 law that gave the Post Office the flexibility to adjust pricing on competitive shipping products such as Express and Priority Mail. The law also simplified the process of changing rates on its monopoly mailing services by tying future increases to adjustments in the Consumer Price Index (CPI). At the same time, USPS was required to ensure that revenues from shipping services adequately covered its costs. The law was the most sweeping change at USPS since the 1971 reorganization that created the present-day postal organization. The 2006 law was also designed to create a level playing field in shipping services between USPS and its private rivals.
Over the years, as digital commerce fundamentally changed the world of mailing and shipping, USPS' shipping business has thrived even as its mailing revenue and volumes have fallen. In its 2014 fiscal year, which ended Sept. 30, USPS' "shipping and package services" volume grew by 300 million pieces, an 8.1-percent increase over the prior fiscal year. First-class mail volume, USPS' most profitable service line, declined 2.2 percent year-over-year. In its fiscal first quarter, shipping and package volume rose by 12.8 percent from the prior-year period, buoyed by a surge in holiday e-commerce traffic. First-class mail volumes fell by 1.1 percent. These trends are expected to continue for years to come, and even USPS executives see no reversal in the decline in mail volumes or revenues.
LACK OF VISIBILITY?
At this point, the opacity of USPS' methodology and disclosures make it impossible to take a good look under the hood, according to the complaints. "We don't have the transparency to make a determination" on whether cross-subsidization is occurring, said Keith Kellison, UPS' vice president of global public affairs. "We know there are red flags," such as a recent USPS disclosure that only 55 percent of USPS costs are tied to specific products, Kellison added.
UPS and others contend that USPS applies costing methodologies from the 1970s to the different and dynamic business environment of today. At the very least, UPS wants the Postal Commission to conduct a thorough review of USPS' accounting practices, and a dedicated regulatory proceeding may be warranted to achieve that goal, Kellison said.
Gail Adams, a spokeswoman for the Postal Commission, declined comment on the status of the current proceeding. Adams noted that, by law, a test is required to ensure monopoly products don't cross-subsidize competitive products. In its most recent compliance report, USPS said the incremental costs of competitive products were $11.2 billion, while revenues were $15.3 billion. Because revenues exceeded incremental costs, there was no cross-subsidy based on USPS' numbers, she said.
In its filing, USPS furnished examples of how it adequately and publicly accounts for investments made to support the growth in its competitive product line.
USPS has its supporters. Jerry Hempstead, a longtime top parcel executive and today head of a consultancy that bears his name, said USPS has been "very disciplined about cost allocation by product for decades," and that it "goes out of its way to prevent any inference that a particular class (of) mail is not carrying its fair share." Hempstead surmised that the UPS and FedEx filings smack of sour grapes because USPS is a formidable competitor in the business-to-consumer segment that has come to dominate U.S. parcel shipping. He also wonders if the private carriers' actions are prompted by their displeasure over USPS raising parcel select rates by 9 percent, while keeping Priority Mail rates unchanged. The increases, which the commission approved in late February, take effect April 26.
Gordon Glazer, who was been involved in postal operations for more than 25 years and is today director of modal optimization strategies for consultancy Shipware LLC, said it's hypocritical for UPS and FedEx to complain about any alleged USPS accounting sleight of hand when they act in concert to raise rates, increase charges for add-on or "accessorial" services, move in concert to change pricing on ground parcels measuring less than 3 cubic feet, and jointly freeze out third-party parcel consultants who negotiate parcel rates on behalf of their clients.
"I think it is a lot easier for them to point the accusing finger at their competitor now more than ever, which is a validation in its own right of the true competition that (USPS) has morphed into," Glazer 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]."
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.