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.
After spending decades with the legendary airline Flying Tigers and then with FedEx Corp., which acquired Tigers nearly 30 years ago, Carl Asmus has forgotten more about air freight than most people ever knew. In addition, as senior vice president of e-commerce for FedEx, Asmus works for a company more closely associated with air shipping than any in history.
So it might have seemed unusual that at a recent conference, Asmus described pitching a prospective customer on FedEx's e-commerce solutions that go across national borders but not even mentioning transport services as part of its value proposition. "All I talked about was making the shopping experience easier for the merchant," Asmus, who also runs FedEx's cross-border e-commerce business, told the gathering. "I didn't talk about transportation."
For Memphis, Tenn.-based FedEx, keeping transport out of the customer dialogue is standard operating procedure for its cross-border strategy. Transportation only happens after someone visits a website, orders an item, and pays for it. For Asmus's unit, the secret sauce is helping a customer in Idaho juggle the many cultural, currency, technological, and commercial variables that come into play once a consumer in Istanbul places an order on its site. A merchant that gets it right on the front end—understanding market demand and implementing a flawless user interface from product availability to payment options—could gain access to markets, and potential repeat business, it could only have dreamed of before. Get it wrong, and a business could watch a market valued today at well over $300 billion and which could be worth three times that in just three years, pass it by. In the latter scenario, the delivery promises of the world's largest and swiftest airfreight network wouldn't amount to a hill of beans.
THE RISE OF CROSS-BORDER E-COMMERCE
The definition of cross-border e-commerce is in the eyes of the beholder. Some make no distinction between cross-border and traditional international e-commerce, given that they both involve movements from one country to another. Consultancy ShipStation, however, frames them as different services. As the company sees it, cross-border e-commerce is exclusively business-to-consumer (B2C), while international can be either B2C or business-to-business (B2B). In a cross-border transaction, the "landed cost"—the combined costs of product, customs duties, taxes, and documentation—is paid up front; in an international e-commerce transaction, customs presents a bill to the shipper or consignee after the fact, according to ShipStation's interpretation.
Today, cross-border e-commerce is, for all practical purposes, practiced in only a handful of countries—the U.S. only for outbound deliveries, Japan, the U.K., Germany, Canada, China, Australia, and South Korea, according to ShipStation; other markets' share of cross-border is too inconsequential to count, the firm said. International e-commerce, by contrast, can be conducted anywhere trade is allowed, ShipStation said.
Cross-border e-commerce is not yet a mature market, which might explain why it's expanding at about 25 percent a year, according to estimates from German air-express giant DHL Express. In conjunction with that expansion, global parcel volume leapt to 65 billion pieces in 2016 from 44 billion in 2014, according to data from information technology specialist Pitney Bowes and research firm eMarketer. Global volumes will rise between 17 and 18 percent a year from 2017 to 2021, according to Pitney Bowes data.
Online ordering between countries is not a passing fad, especially as the Internet allows consumers across the planet to buy stuff that they can't get in their home market or that they can find cheaper elsewhere. About 46 percent of U.K. online shoppers order goods from outside the country, while 21 percent of Germans do, according to estimates from multinational freight forwarder Seko Logistics, based in Itasca, Ill. About 78 percent of all global B2C transactions never touch North America, said Hermes Nextec, an e-commerce unit of the German firm Hermes Group.
Given the long distances and customer demands for speedy deliveries, it would seem to make sense for producers and retailers to build distribution footprints across the globe and fulfill over shorter routes. But that's not the case, said a recent DHL survey of 1,800 e-tailers. Retailers and manufacturers that offer a "premium" shipping service grow 1.6 times as fast as those who don't, according to the survey. That's because expedited shipping allows international e-tailers to compete with their domestic rivals for the "home advantage" of shorter delivery times, DHL said. U.S. brands, which are blessed by having nearly insatiable foreign demand for their products, will bring goods made in low-cost regions into the U.S., where they're then air shipped to their final foreign destinations, said Brian Bourke, Seko's vice president of marketing.
International e-commerce is getting a boost from efforts to raise the value threshold of goods not subject to extensive customs documentation requirements. Last year, the U.S. raised the so-called de minimis threshold to $800 from $200 per shipment, enabling a broader range of products to clear U.S. Customs free of cumbersome paperwork. Eugene Laney, head of international affairs for DHL Express's U.S. operations, said DHL is actively lobbying foreign governments to raise their respective de minimis thresholds because it would provide a substantial tailwind to global commercial activity.
DO YOU NEED TO GET IT RIGHT? OUI!
For all its potential, cross-border e-commerce is a challenge to execute, and the risks of failure are high. Asmus reckoned that only 3 percent out of every 50,000 international website hits result in an item's being placed in a shopping cart. Only 7 percent of that sliver results in an actual sale, he said.
Faced with such long odds, nothing can be left to chance, especially since a consumer in Hungary expects the same seamless experience for a shipment traveling from the U.S. that a customer in Boston would expect for an order fulfilled in Philadelphia. A homogenous pOréal is out of the question. Country-specific websites must be built with content containing time zone, language, currency, and landed-cost details customized for the end consumer. A best-in-class mobile payment system is not a luxury for merchants, but a necessity, experts added.
Compliance is also critical, as each country and region has its own cultural rituals. End customers in Asia are more concerned with product authenticity than price because of the many stories surrounding product counterfeiting in the region, added Laney. By contrast, European consumers focus more on price, he said.
Manufacturers and retailers must also be concerned with the specter of government regulation, particularly because most customs inspectors are unfamiliar with cross-border e-commerce transactions and the parties involved in them. The traditional international air shipment has moved in pallets and containers, and as part of a B2B transaction. Cross-border e-commerce often moves in one- or two-item quantities, and typically between a merchant and a consumer. The B2B channel involves participants known in the customs chain, while the B2C channel includes players who are unfamiliar to inspectors, said Laney. What's more, B2C shipments could be composed of low-value items that might be fraudulent, whereas B2B traffic is usually bona fide given the high shipment value involved, he said.
The complexities of cross-border online trade seem to augur favorably for multinational freight forwarders, who have the networks and the expertise to support a merchant looking to expand into foreign markets. Seko has been at cross-border e-commerce for five to six years, according to Bourke. Five years ago, Seko was not involved in Asian cross-border business; today, Asia is its fastest-growing market, Bourke said.
The German forwarding giant DB Schenker is also moving aggressively into cross-border e-commerce, but it is doing so with partners rather than on its own, said Jochen Thewes, chairman of Schenker's board of management. "Digitization requires companies to be fast to market and to build quick solutions," Thewes said. "This means working with providers to buy services and technology."
Asmus may be sanguine about the role of transportation in making cross-border e-commerce work, but others are not. In an October 2017 survey of 1,200 retailers from eight countries and 12,000 consumers from 11 global markets, Pitney Bowes found that 97 percent of retailers understand the need for fast and reliable end-to-end shipping management and that 52 percent are actively evaluating or researching such services. "Clearly, delivery experiences and speed of fulfillment play a key role in securing and retaining new customers and promoting a long-term relationship more now than ever before," according to the survey.
The global airfreight market has been on fire this year following seven years of malaise. The growth of cross-border e-commerce is a part of that surge, and current trends indicate that it will play an even larger role. Consumers' need for speed will demand the fastest route from A to B, and businesses competing for share of this massive market may find they have no other option than air.
Asked if e-commerce could spur the next golden era for air freight, Bourke replied, "You bet your ass. And you can quote me."
The consulting firm Accenture has acquired Staufen AG, a German management consulting firm, saying the move will expand Accenture’s capabilities to drive operational excellence and competitiveness in manufacturing and supply chains.
Specifically, adding Staufen will help Accenture serve clients in discrete manufacturing industries including automotive, aerospace and defense, industrial goods, and medical equipment.
According to Accenture it made the deal because manufacturers are under pressure to mitigate supply chain disruptions, geopolitical tensions, and fluctuating tariffs while staying abreast of rapid technological advances. To meet those needs, Staufen brings expertise in helping clients optimize their entire value chains, drive value with digital manufacturing initiatives, and improve overall businesses performance.
Staufen’s service portfolio includes solutions for Industry 4.0, supply chain management, and organizational change as well as data-driven tools, continuous improvement techniques, and lean management principles. Its approach enhances clients’ product design, shopfloor processes, time to market, and sustainability efforts, reducing costs, eliminating inefficiencies, and optimizing production capacity, the company said.
“Manufacturers must continuously improve their entire value chains to stay competitive,” Matthias Hégelé, Accenture’s supply chain and operations lead for Germany, Austria, and Switzerland, said in a release.
“The acquisition of Staufen aligns with our strategy to reinvent supply chains and manufacturing for clients. We will combine Staufen’s proven expertise in operational excellence and value chain transformation with our capabilities in digital technologies, such as AI, generative AI, digital twins and supply chain and manufacturing software platforms, to help clients transform their core value chains, improving efficiency and productivity, supporting sustainable practices, and building resilient, autonomous systems,” Hégelé said.
Part of the reason for that situation is that companies can’t adjust to tariffs overnight by finding new suppliers. “Supply chains are complex. Retailers continue to engage in diversification efforts. Unfortunately, it takes significant time to move supply chains, even if you can find available capacity,” NRF Vice President for Supply Chain and Customs Policy Jonathan Gold said in a release.
“While we support the need to address the fentanyl crisis at our borders, new tariffs on China and other countries will mean higher prices for American families,” Gold said. “Retailers have engaged in mitigation strategies to minimize the potential impact of tariffs, including frontloading of some products, but that can lead to increased challenges because of added warehousing and related costs. We hope to resolve our outstanding border security issues as quickly as possible because there will be a significant impact on the economy if increased tariffs are maintained and expanded.”
Hackett Associates Founder Ben Hackett said tariffs on Canada and Mexico would initially have minimal impact at ports because most imports from either country move by truck, rail or pipeline. In the long term, tariffs on goods that receive final manufacturing in Canada or Mexico but originate elsewhere could prompt an increase in direct maritime imports to the U.S. In the meantime, port cargo “could be badly hit” if tariffs on overseas Asian and European nations increase prices and prompt consumers to buy less, he said.
“At this stage, the situation is fluid, and it’s too early to know if the tariffs will be implemented, removed or further delayed,” Hackett said. “As such, our view of North American imports has not changed significantly for the next six months.”
U.S. ports covered by Global Port Tracker handled 2.14 million twenty-foot equivalent units (TEUs) in December, although the Port of New York and New Jersey and the Port of Miami have yet to report final data. That was down 0.9% from November but up 14.4% year over year, and would be the busiest December on record. For the year, December brought 2024 to a total of 25.5 million TEU, up 14.8% from 2023 and the highest level since 2021’s record of 25.8 million TEU during the pandemic.
Global Port Tracker provides historical data and forecasts for the U.S. ports of Los Angeles/Long Beach, Oakland, Seattle and Tacoma on the West Coast; New York/New Jersey, Port of Virginia, Charleston, Savannah, Port Everglades, Miami and Jacksonville on the East Coast, and Houston on the Gulf Coast.
Having reported on the supply chain world for some 25 years, I've seen technologies come and go. Many were once touted as the best thing since sliced bread but either failed to live up to the hype or else had to simmer a few years before they caught on.
Remember the hoopla surrounding dot-com retail? In the late 1990s, we were told that stores as we knew them would eventually go away, to be totally replaced by online shopping. The ease and convenience of e-commerce made that a reasonable expectation. But in March 2000, the bubble burst, and a host of online retailers closed their virtual doors forever. Of course, online shopping is still very much with us, and its share of total retail sales is growing by the year. Maybe we'll get to that retail seventh heaven someday, but it's taking much longer than originally predicted.
Then there's RFID (radio-frequency identification). These small electronic tags were going to replace barcodes largely because of the vast amount of data they can hold and their capacity to update information.
In 2003, Walmart famously demanded that its top 100 suppliers affix RFID tags to all pallets and cases shipped to its DCs. We figured that if Walmart had gone all in on RFID, the rest of the industry would automatically follow. Well, not so fast. It's true that after years of stutter-step progress, Walmart today is more heavily invested in RFID than ever. But in the rest of the world, the humble barcode is still king.
A more recently hyped technology is blockchain. It was actually conceived back in 1982 but remained just a concept until 2008, when a person (or persons) using the name "Satoshi Nakamoto" created an actual blockchain to serve as the public distributed ledger for cryptocurrency transactions. Blockchain was expected to revolutionize the way supply chain partners do business. But it, too, has been a bit slow to take off, and it's still unclear how the blockchain story will play out.
That brings us to the latest potentially game-changing technology: artificial intelligence (AI). In some ways, AI is really just data analytics on steroids. Supply chains have relied on data analytics for decades—the difference now is the promise of greater accuracy and better simulations. Will it ultimately change everything we do in supply chain management? Maybe. But it may take a while. A November report from workplace tools developer Slack showed that AI adoption rates among U.S. workers had slowed in the last quarter, while a recent analysis of open supply chain jobs by software integration specialist Cleo found that only 2% of open jobs required AI skills.
So is AI just another fad or a truly transformative technology? It appears we'll need a few good use cases before we can make that call.
Economic activity in the logistics industry expanded in January, growing at its fastest clip in more than two years, according to the latest Logistics Managers’ Index (LMI) report, released this week.
The LMI jumped nearly five points from December to a reading of 62, reflecting continued steady growth in the U.S. economy along with faster-than-expected inventory growth across the sector as retailers, wholesalers, and manufacturers attempted to manage the uncertainty of tariffs and a changing regulatory environment. The January reading represented the fastest rate of expansion since June 2022, the LMI researchers said.
An LMI reading above 50 indicates growth across warehousing and transportation markets, and a reading below 50 indicates contraction. The LMI has remained in the mid- to high 50s range for most of the past year, indicating moderate, consistent growth in logistics markets.
Inventory levels rose 8.5 points from December, driven by downstream retailers stocking up ahead of the Trump administration’s potential tariffs on imports from Mexico, Canada, and China. Those increases led to higher costs throughout the industry: inventory costs, warehousing prices, and transportation prices all expanded to readings above 70, indicating strong growth. This occurred alongside slowing growth in warehousing and transportation capacity, suggesting that prices are up due to demand rather than other factors, such as inflation, according to the LMI researchers.
The LMI is a monthly survey of logistics managers from across the country. It tracks industry growth overall and across eight areas: inventory levels and costs; warehousing capacity, utilization, and prices; and transportation capacity, utilization, and prices. The report is released monthly by researchers from Arizona State University, Colorado State University, Rochester Institute of Technology, Rutgers University, and the University of Nevada, Reno, in conjunction with the Council of Supply Chain Management Professionals (CSCMP).
As commodities go, furniture presents its share of manufacturing and distribution challenges. For one thing, it's bulky. Second, its main components—wood and cloth—are easily damaged in transit. Third, much of it is manufactured overseas, making for some very long supply chains with all the associated risks. And finally, completed pieces can sit on the showroom floor for weeks or months, tying up inventory dollars and valuable retail space.
In other words, the furniture market is ripe for disruption. And John "Jay" Rogers wants to be the catalyst. In 2022, he cofounded a company that takes a whole new approach to furniture manufacturing—one that leverages the power of 3D printing and robotics. Rogers serves as CEO of that company, Haddy, which essentially aims to transform how furniture—and all elements of the "built environment"—are designed, manufactured, distributed, and, ultimately, recycled.
Rogers graduated from Princeton University and went to work for a medical device startup in China before moving to a hedge fund company, where he became a Chartered Financial Analyst (CFA). After that, he joined the U.S. Marine Corps, serving eight years in the infantry. Following two combat tours, he earned an MBA from the Harvard Business School and became a consultant for McKinsey & Co.
During this time, he founded Local Motors, a next-generation vehicle manufacturer that launched the world's first 3D-printed car, the Strati, in 2014. In 2021, he brought the technology to the furniture industry to launch Haddy. The father of four boys, Rogers is also a director of the RBR Foundation, a philanthropic organization focused on education and health care.
Rogers spoke recently with DC Velocity Group Editorial Director David Maloney on an episode of the "Logistics Matters" podcast.
Q: Could you tell us about Haddy and how this unique company came to be?
A: Absolutely. We have believed in the future of distributed digital manufacturing for a long time. The world has gone from being heavily globalized to one where lengthy supply chains are a liability—thanks to factors like the growing risk of terrorist attacks and the threat of tariffs. At the same time, there are more capabilities to produce things locally. Haddy is an outgrowth of those general trends.
Adoption of the technologies used in 3D printing has been decidedly uneven, although we do hear about applications like tissue bioprinting and food printing as well as the printing of trays for dental aligners. At Haddy, we saw an opportunity to take advantage of large-scale structural printing to approach the furniture and furnishings industry. The technology and software that make this possible are already here.
Q: Furniture is a very mature market. Why did you see this as a market that was ripe for disruption?
A:The furniture market has actually been disrupted many times in the last 200 years. The manufacturing of furniture for U.S. consumption originally took place in England. It then moved to Boston and from there to New Amsterdam, the Midwest, and North Carolina. Eventually, it went to Taiwan, then China, and now Vietnam, Indonesia, and Thailand. And each of those moves brought some type of disruption.
Other disruptions have been based on design. You can look at things like the advent of glue-laminated wood with Herman Miller, MillerKnoll, and the Eames [furniture design and manufacturing] movement. And you can look at changes in the way manufacturing is powered—the move from manual operations to machine-driven operations powered by steam and electricity. So the furniture industry has been continuously disrupted, sometimes by labor markets and sometimes by machines and methods.
What's happening now is that we're seeing changes in the way that labor is applied in furniture manufacturing. Furniture has traditionally been put together by human hands. But today, we have an opportunity to reassign those hands to processes that take place around the edges of furniture production. The hands are now directing robotics through programming and design; they're not actually making the furniture.
And so, we see this mature market as being one that's been continuously disrupted during the last 200 years. And this disruption now has a lot to do with changing the way that labor interacts with the making of furniture.
Q: How do your 3D printers actually create the furniture?
A:All 3D printing is not the same. The 3D printers we use are so-called "hybrid" systems. When we say hybrid, what we mean is that they're not just printers—they are holders, printers, polishers, and cutters, and they also do milling and things like that. We measure things and then print things, which is the additive portion. Then we can do subtractive and polishing work—re-measuring, moving, and printing parts again. And so, these hybrid systems are the actual makers of the furniture.
Q: What types of products are you making?
A: We've started with hardline or case goods, as they're sometimes known, for both residential and commercial use—cabinets, wall bookshelves, freestanding bookshelves, tables, rigid chairs, planters, and the like. Basically, we've been concentrating on products that don't have upholstery.
It's not that upholstery isn't necessary in furniture, as it is used in many pieces. But right now, we have found that digital furniture manufacturing becomes analog again when you have to factor in the sewing process. And so, to move quickly and fully leverage the advantages of digital manufacturing, we're sticking to the hardline groups, except for a couple of pieces that we have debuted that have 3D-printed cushions, which are super cool.
Q: Of course, 3D printers create objects in layers. What types of materials are you running through your 3D printers to create this furniture?
A: We use recycled materials, primarily polymer composites—a bio-compostable polymer or a synthetic polymer. We look for either recycled or bio-compostable [materials], which we then reinforce with fibers and fillers, and that's what makes them composites. To create the bio-compostables, we marry them with bio-fibers, such as hemp or bamboo. For synthetic materials, we marry them with things like glass or carbon fibers.
Q: Does producing goods via 3D printing allow you to customize products easily?
A: Absolutely. The real problem in the furniture and furnishings industries is that when you tool up to make something with a jig, a fixture, or a mold, you tend to be less creative because you now feel you have to make and sell a lot of that item to justify the investment.
One of the great promises of 3D printing is that it doesn't have a mold and doesn't require tooling. It exists in the digital realm before it becomes physical, and so customization is part and parcel of the process.
I would also add that people aren't necessarily looking for one-off furniture. Just because we can customize doesn't mean we're telling customers that once we've delivered a product, we break the digital mold, so to speak. We still feel that people like styles and trends created by designers, but the customization really allows enterprise clients—like businesses, retailers, and architects—to think more freely.
Customization is most useful in allowing people to "iterate" quickly. Our designers can do something digitally first without having to build a tool, which frees them to be more creative. Plus, because our material is fully recyclable, if we print something for the first time and find it doesn't work, we can just recycle it. So there's really no penalty for a failed first printing—in fact, those failures bring their own rewards in the form of lessons we can apply in future digital and physical iterations.
Q: You currently produce your furniture in an automated microfactory in Florida, with plans to set up several more. Could you talk a little about what your microfactory looks like and how you distribute the finished goods?
A: Our microfactory is a 30,000-square-foot box that mainly contains the robots that make our furniture along with shipping docks. But we don't intend for our microfactories to be storage warehouses and trans-shipment facilities like the kind you'd typically see in the furniture industry—all of the trappings of a global supply chain. Instead, a microfactory is meant to be a site where you print the product, put it on a dock, and then ship it out. So a microfactory is essentially an enabler of regional manufacturing and distribution.
Q: Do you manufacture your products on a print-to-order basis as opposed to a print-to-stock model?
A: No. We may someday get to the point where we receive an order digitally, print it, and then send it out on a truck the next day. But right now, we aren't set up to do a mini-delivery to one customer out of a microfactory.
We are an enterprise company that partners with architects, designers, builders, and retailers, who then distribute our furnishings to their customers. We are not trying to go direct-to-consumer at this stage. It's not the way a microfactory is set up to distribute goods.
Q: You've mentioned your company's use of recycled materials. Could you talk a little bit about other ways you're looking to reduce waste and help support a circular economy?
A: Yes. Sustainability and a circular economy are really something that you have to plan for. In our case, our plans call for moving toward a distributed digital manufacturing model, where we establish microfactories in various regions around the world to serve customers within a 10-hour driving radius of the factory. That is a pretty large area, so we could cover the United States with just four or five microfactories.
That also means that we can credibly build our recycling network as part of our microfactory setup. As I mentioned, we use recycled polymer stock in our production, so we're keeping that material out of a landfill. And then we tell our enterprise customers that while the furniture they're buying is extremely durable, when they're ready to run a special and offer customers a credit for turning in their used furniture, we'll buy back the material. Buying back that material actually reduces our costs because it's already been composited and created and recaptured. So our microfactory network is well designed for circularity in concert with our enterprise customers.