Maritime industry faces obstacles to efficiency, productivity
Ocean carriers, ports, and drayage truckers are confronting challenges that will ultimately affect shippers, according to speakers at a recent trade and transportation conference.
Contributing Editor Toby Gooley is a writer and editor specializing in supply chain, logistics, and material handling, and a lecturer at MIT's Center for Transportation & Logistics. She previously was Senior Editor at DC VELOCITY and Editor of DCV's sister publication, CSCMP's Supply Chain Quarterly. Prior to joining AGiLE Business Media in 2007, she spent 20 years at Logistics Management magazine as Managing Editor and Senior Editor covering international trade and transportation. Prior to that she was an export traffic manager for 10 years. She holds a B.A. in Asian Studies from Cornell University.
Fuel mandates, potential carrier consolidation, and headaches for drayage truckers are among the key obstacles facing the maritime industry, according to speakers at the recent Coalition of New England Companies for Trade (CONECT)23rd Annual Northeast Trade and Transportation Conference, held in Newport, R.I., in April. Such issues stand out among the many challenges that threaten the efficiency and profitability of every direct stakeholder and, ultimately, their customers, the experts said, highlighting the following:
New rules mandating low-sulfur fuel. Effective January 1, 2020, the International Maritime Organization (IMO) will require ocean carriers to use either expensive low-sulfur fuel or employ "scrubber" technology that will remove most sulfur from their ships' emissions. Compliance could add $10 billion to $15 billion annually to carriers' costs, said Gary Ferrulli, CEO of Global Transport & Logistics Consulting. As a result, carriers want to change the formula for applying fuel ("bunker") surcharges to reflect the actual average cost of fuel in specified markets, rather than basing it on quarterly projections, he said. Although shippers understand the necessity of adjusting surcharges, Ferrulli said they are concerned about the potentially sizable increase in their own costs.
In a separate presentation, keynote speaker Howard Finkel, executive vice president of trade for COSCO Container Lines Americas Inc., identified potential roadblocks to implementation of the IMO mandate by the deadline. These include the possibility that there won't be enough low-sulfur fuel available, the limited number of companies that are qualified to retrofit ships with scrubbers, and the fact that not all countries allow scrubbers. Finkel said that, depending on how it affects carriers' costs, compliance with the low-sulfur requirement could "make or break" carriers' profitability in 2020.
Potential for carrier consolidation.Low freight rates and elusive profits raise the specter of carrier mergers, acquisitions, and bankruptcies. COSCO's Finkel said he does not foresee any mergers or bankruptcies among major container carriers right now, but noted that any near-term acquisitions would likely involve smaller regional carriers. If carriers can continue to keep inbound and outbound capacity in reasonable balance while successfully managing the cost impact of the low-sulfur mandate, then stability is likely, he said.
Ferrulli noted that carriers on the trans-Pacific lanes have been managing capacity by withdrawing ships and sailings. Rates are about $100 higher than they were at the same point in 2018, he said, noting that his clients' service-contract rates are about 7 percent to 15 percent higher than they were last year. He cautioned that some carriers will be taking delivery of bigger ships in 2020 and 2021, which could make overcapacity an issue again. Ferrulli also questioned the financial viability of some Asian carriers that are subsidized by their national governments and therefore don't have to worry much about profits—a "flawed business model" that is not sustainable, he said. He also predicted changes in Europe: if the European Union lets exemptions that allow carriers to operate joint services and alliances in European trade lanes expire next year, "you are going to see [some] carriers in those agreements disappear," he said. His advice to shippers: Read carriers' financials carefully, understand the implications of working with service providers that consistently lose money, and have a plan to manage the disruption that will arise if carriers merge or go out of business.
Constraints on drayage truckers' productivity. The majority of drayage truckers—the carriers that shippers rely on to pick up and drop-off loaded and empty containers—are independent contractors. Others are small, local motor carriers, and some are larger regional networks. This segment of the transportation industry is highly fragmented; the 10 largest drayage carriers represent just 8 percent of total capacity, according to David McLaughlin, chief operating officer of one of those companies, RoadOne IntermodaLogistics, who addressed productivity concerns in this sector during a separate panel discussion.
Shippers typically pay drayage carriers a set rate per container. To make a living, drivers need to handle multiple round-trips a day. But congestion at some seaport and intermodal terminals and, once they get in the gate, difficulties in getting container chassis, mean that truckers serving those facilities spend too much of their day waiting in lines. This situation was exacerbated late last year and early in 2019, especially on the West Coast, when backlogs developed as shippers scrambled to bring in as many containers as possible before higher tariffs on Chinese goods went into effect. In addition, McLaughlin said, the giant ships that have increased the numbers of containers ports must handle at one time have hurt drayage productivity by contributing to congestion, delays, and chassis shortages at ports and off-dock intermodal ramps. In a bid to reduce congestion, some container terminals have moved chassis off dock, adding a time-consuming stop for drivers, he added.
According to McLaughlin, the federally mandated hours-of-service (HOS) limitations on the number of hours drivers can work in a day are also having a negative impact on drayage truckers' productivity. He estimated that the drayage industry is seeing a 10 percent decline in productivity, and thus fewer container "turns" per day, as a result of compliance with the regulations. Meanwhile, railroads have been reducing the number of intermodal terminals they operate. As a result, drivers in some areas have to travel further to pick up and drop off containers, which he said reduces the number of trips they can make in a day. With big companies like Amazon, Uber, and Lyft "sucking away" drivers, sometimes at "double the rates that drayage companies can offer," already high driver turnover rates are climbing and recruiting is becoming increasingly difficult, he said. Taken together, several speakers agreed, these challenges suggest that a shortage of drayage capacity may be in the offing.
The New York-based industrial artificial intelligence (AI) provider Augury has raised $75 million for its process optimization tools for manufacturers, in a deal that values the company at more than $1 billion, the firm said today.
According to Augury, its goal is deliver a new generation of AI solutions that provide the accuracy and reliability manufacturers need to make AI a trusted partner in every phase of the manufacturing process.
The “series F” venture capital round was led by Lightrock, with participation from several of Augury’s existing investors; Insight Partners, Eclipse, and Qumra Capital as well as Schneider Electric Ventures and Qualcomm Ventures. In addition to securing the new funding, Augury also said it has added Elan Greenberg as Chief Operating Officer.
“Augury is at the forefront of digitalizing equipment maintenance with AI-driven solutions that enhance cost efficiency, sustainability performance, and energy savings,” Ashish (Ash) Puri, Partner at Lightrock, said in a release. “Their predictive maintenance technology, boasting 99.9% failure detection accuracy and a 5-20x ROI when deployed at scale, significantly reduces downtime and energy consumption for its blue-chip clients globally, offering a compelling value proposition.”
The money supports the firm’s approach of "Hybrid Autonomous Mobile Robotics (Hybrid AMRs)," which integrate the intelligence of "Autonomous Mobile Robots (AMRs)" with the precision and structure of "Automated Guided Vehicles (AGVs)."
According to Anscer, it supports the acceleration to Industry 4.0 by ensuring that its autonomous solutions seamlessly integrate with customers’ existing infrastructures to help transform material handling and warehouse automation.
Leading the new U.S. office will be Mark Messina, who was named this week as Anscer’s Managing Director & CEO, Americas. He has been tasked with leading the firm’s expansion by bringing its automation solutions to industries such as manufacturing, logistics, retail, food & beverage, and third-party logistics (3PL).
Supply chains continue to deal with a growing volume of returns following the holiday peak season, and 2024 was no exception. Recent survey data from product information management technology company Akeneo showed that 65% of shoppers made holiday returns this year, with most reporting that their experience played a large role in their reason for doing so.
The survey—which included information from more than 1,000 U.S. consumers gathered in January—provides insight into the main reasons consumers return products, generational differences in return and online shopping behaviors, and the steadily growing influence that sustainability has on consumers.
Among the results, 62% of consumers said that having more accurate product information upfront would reduce their likelihood of making a return, and 59% said they had made a return specifically because the online product description was misleading or inaccurate.
And when it comes to making those returns, 65% of respondents said they would prefer to return in-store, if possible, followed by 22% who said they prefer to ship products back.
“This indicates that consumers are gravitating toward the most sustainable option by reducing additional shipping,” the survey authors said in a statement announcing the findings, adding that 68% of respondents said they are aware of the environmental impact of returns, and 39% said the environmental impact factors into their decision to make a return or exchange.
The authors also said that investing in the product experience and providing reliable product data can help brands reduce returns, increase loyalty, and provide the best customer experience possible alongside profitability.
When asked what products they return the most, 60% of respondents said clothing items. Sizing issues were the number one reason for those returns (58%) followed by conflicting or lack of customer reviews (35%). In addition, 34% cited misleading product images and 29% pointed to inaccurate product information online as reasons for returning items.
More than 60% of respondents said that having more reliable information would reduce the likelihood of making a return.
“Whether customers are shopping directly from a brand website or on the hundreds of e-commerce marketplaces available today [such as Amazon, Walmart, etc.] the product experience must remain consistent, complete and accurate to instill brand trust and loyalty,” the authors said.
When you get the chance to automate your distribution center, take it.
That's exactly what leaders at interior design house
Thibaut Design did when they relocated operations from two New Jersey distribution centers (DCs) into a single facility in Charlotte, North Carolina, in 2019. Moving to an "empty shell of a building," as Thibaut's Michael Fechter describes it, was the perfect time to switch from a manual picking system to an automated one—in this case, one that would be driven by voice-directed technology.
"We were 100% paper-based picking in New Jersey," Fechter, the company's vice president of distribution and technology, explained in a
case study published by Voxware last year. "We knew there was a need for automation, and when we moved to Charlotte, we wanted to implement that technology."
Fechter cites Voxware's promise of simple and easy integration, configuration, use, and training as some of the key reasons Thibaut's leaders chose the system. Since implementing the voice technology, the company has streamlined its fulfillment process and can onboard and cross-train warehouse employees in a fraction of the time it used to take back in New Jersey.
And the results speak for themselves.
"We've seen incredible gains [from a] productivity standpoint," Fechter reports. "A 50% increase from pre-implementation to today."
THE NEED FOR SPEED
Thibaut was founded in 1886 and is the oldest operating wallpaper company in the United States, according to Fechter. The company works with a global network of designers, shipping samples of wallpaper and fabrics around the world.
For the design house's warehouse associates, picking, packing, and shipping thousands of samples every day was a cumbersome, labor-intensive process—and one that was prone to inaccuracy. With its paper-based picking system, mispicks were common—Fechter cites a 2% to 5% mispick rate—which necessitated stationing an extra associate at each pack station to check that orders were accurate before they left the facility.
All that has changed since implementing Voxware's Voice Management Suite (VMS) at the Charlotte DC. The system automates the workflow and guides associates through the picking process via a headset, using voice commands. The hands-free, eyes-free solution allows workers to focus on locating and selecting the right item, with no paper-based lists to check or written instructions to follow.
Thibaut also uses the tech provider's analytics tool, VoxPilot, to monitor work progress, check orders, and keep track of incoming work—managers can see what orders are open, what's in process, and what's completed for the day, for example. And it uses VoxTempo, the system's natural language voice recognition (NLVR) solution, to streamline training. The intuitive app whittles training time down to minutes and gets associates up and working fast—and Thibaut hitting minimum productivity targets within hours, according to Fechter.
EXPECTED RESULTS REALIZED
Key benefits of the project include a reduction in mispicks—which have dropped to zero—and the elimination of those extra quality-control measures Thibaut needed in the New Jersey DCs.
"We've gotten to the point where we don't even measure mispicks today—because there are none," Fechter said in the case study. "Having an extra person at a pack station to [check] every order before we pack [it]—that's been eliminated. Not only is the pick right the first time, but [the order] also gets packed and shipped faster than ever before."
The system has increased inventory accuracy as well. According to Fechter, it's now "well over 99.9%."
IT projects can be daunting, especially when the project involves upgrading a warehouse management system (WMS) to support an expansive network of warehousing and logistics facilities. Global third-party logistics service provider (3PL) CJ Logistics experienced this first-hand recently, embarking on a WMS selection process that would both upgrade performance and enhance security for its U.S. business network.
The company was operating on three different platforms across more than 35 warehouse facilities and wanted to pare that down to help standardize operations, optimize costs, and make it easier to scale the business, according to CIO Sean Moore.
Moore and his team started the WMS selection process in late 2023, working with supply chain consulting firm Alpine Supply Chain Solutions to identify challenges, needs, and goals, and then to select and implement the new WMS. Roughly a year later, the 3PL was up and running on a system from Körber Supply Chain—and planning for growth.
SECURING A NEW SOLUTION
Leaders from both companies explain that a robust WMS is crucial for a 3PL's success, as it acts as a centralized platform that allows seamless coordination of activities such as inventory management, order fulfillment, and transportation planning. The right solution allows the company to optimize warehouse operations by automating tasks, managing inventory levels, and ensuring efficient space utilization while helping to boost order processing volumes, reduce errors, and cut operational costs.
CJ Logistics had another key criterion: ensuring data security for its wide and varied array of clients, many of whom rely on the 3PL to fill e-commerce orders for consumers. Those clients wanted assurance that consumers' personally identifying information—including names, addresses, and phone numbers—was protected against cybersecurity breeches when flowing through the 3PL's system. For CJ Logistics, that meant finding a WMS provider whose software was certified to the appropriate security standards.
"That's becoming [an assurance] that our customers want to see," Moore explains, adding that many customers wanted to know that CJ Logistics' systems were SOC 2 compliant, meaning they had met a standard developed by the American Institute of CPAs for protecting sensitive customer data from unauthorized access, security incidents, and other vulnerabilities. "Everybody wants that level of security. So you want to make sure the system is secure … and not susceptible to ransomware.
"It was a critical requirement for us."
That security requirement was a key consideration during all phases of the WMS selection process, according to Michael Wohlwend, managing principal at Alpine Supply Chain Solutions.
"It was in the RFP [request for proposal], then in demo, [and] then once we got to the vendor of choice, we had a deep-dive discovery call to understand what [security] they have in place and their plan moving forward," he explains.
Ultimately, CJ Logistics implemented Körber's Warehouse Advantage, a cloud-based system designed for multiclient operations that supports all of the 3PL's needs, including its security requirements.
GOING LIVE
When it came time to implement the software, Moore and his team chose to start with a brand-new cold chain facility that the 3PL was building in Gainesville, Georgia. The 270,000-square-foot facility opened this past November and immediately went live running on the Körber WMS.
Moore and Wohlwend explain that both the nature of the cold chain business and the greenfield construction made the facility the perfect place to launch the new software: CJ Logistics would be adding customers at a staggered rate, expanding its cold storage presence in the Southeast and capitalizing on the location's proximity to major highways and railways. The facility is also adjacent to the future Northeast Georgia Inland Port, which will provide a direct link to the Port of Savannah.
"We signed a 15-year lease for the building," Moore says. "When you sign a long-term lease … you want your future-state software in place. That was one of the key [reasons] we started there.
"Also, this facility was going to bring on one customer after another at a metered rate. So [there was] some risk reduction as well."
Wohlwend adds: "The facility plus risk reduction plus the new business [element]—all made it a good starting point."
The early benefits of the WMS include ease of use and easy onboarding of clients, according to Moore, who says the plan is to convert additional CJ Logistics facilities to the new system in 2025.
"The software is very easy to use … our employees are saying they really like the user interface and that you can find information very easily," Moore says, touting the partnership with Alpine and Körber as key to making the project a success. "We are on deck to add at least four facilities at a minimum [this year]."