Private fleets and dedicated operations: A wider window of opportunity?
The desire for reliable, high-quality service has long been the basis of private carriage’s appeal. Pandemic-fueled disruptions and widespread market uncertainty will only up the ante.
Gary Frantz is a contributing editor for DC Velocity and its sister publication CSCMP's Supply Chain Quarterly, and a veteran communications executive with more than 30 years of experience in the transportation and logistics industries. He's served as communications director and strategic media relations counselor for companies including XPO Logistics, Con-way, Menlo Logistics, GT Nexus, Circle International Group, and Consolidated Freightways. Gary is currently principal of GNF Communications LLC, a consultancy providing freelance writing, editorial and media strategy services. He's a proud graduate of the Journalism program at California State University–Chico.
For the trucking industry, the Covid-19 pandemic has brought into stark relief something that businesses have recognized for some time and everyday citizens are now starting to truly appreciate: Trucking is the foundation of not just the economy, but of virtually every product consumers rely upon to maintain their daily lives.
The past two months have presented unprecedented challenges. What were carefully planned and optimized distribution networks have been thrown into disarray. Some markets, such as “essential” grocery, consumer staples, health care, and medical goods, are bursting at the seams with freight. Other segments, such as the more traditional less-than-truckload (LTL) and truckload shipments generated by small-business commercial, retail, industrial, and manufacturing operations, have disappeared as these businesses have gone dark and workers sent home under shelter-in-place mandates.
The good news: Truck drivers are being widely lauded for their courage, perseverance, and professionalism, braving difficult and sometimes dangerous conditions to deliver critically needed goods. Seldom in history has the importance of trucking to America’s financial and physical well-being been demonstrated so clearly, particularly since some 71% of all freight tonnage moves in the back of a truck, according to the American Trucking Associations.
And while the majority of these volumes move on commercial, for-hire LTL, and full-truckload carriers, one outcome of the market’s pandemic-fueled disruption has been rising interest in:
Purpose-designed dedicated operations, where truckload carriers assign a set of assets (trucks and drivers) and operate a “mini” network exclusively on behalf of that specific shipper, and
Private fleet operations, running within a larger non-trucking organization and providing secure, predictable product velocity and flow for some of the nation’s biggest enterprises.
These fleet options are finding a growing window of opportunity as shippers scramble to lock in reliable capacity, operational consistency, and high-quality service—and to secure protection against dramatic supply/demand swings in the market.
LOCKING IN CAPACITY
Today’s environment—with its widespread uncertainty about the immediate future—is not unlike the market that occurred shortly after the 9/11 terrorist attacks, observes Don Digby Jr., president of Denver, Colorado-based refrigerated carrier Navajo Express. “The biggest demand is for secure capacity,” he notes. Shippers want “to know they’ll have the trucks. That [desire] has never been more relevant or prevalent than it is today.”
John Bozec, senior vice president and general manager, van truckload, at Green Bay, Wisconsin-based truckload carrier Schneider, agrees that predictable service at high levels is “a driving force” behind increased interest in dedicated. “The bar … is only getting higher,” he notes. Bozec cites three determining factors, especially for dedicated solutions addressing complex needs: “The ability to have capacity that is locked in and that [shippers] can rely on, at a price point they know, and [confidence in] the ability to get a great delivery experience. [That’s] why they want more dedicated and not less.”
The current environment notwithstanding, increased interest in dedicated services also continues to be driven by e-commerce–related traffic, observes Eric Downing, senior vice president, dedicated for Omaha, Nebraska-based Werner Enterprises. “Demand for dedicated services has increased, especially as e-commerce [volumes] have expanded and customer expectations for next-day and same-day delivery have increased,” he says. “As shippers move to get their products closer to customers, these types of transportation needs usually fit well within the dedicated model.”
Downing noted that while cost is always part of the equation, shippers looking to dedicated typically are pursuing a larger strategy, often around three primary goals:
1. High levels of service quality, normally 99% percent on time or better
2. Longer-term partnerships where the carrier is working closely with the shipper to drive improvements and efficiencies in the overall supply chain
3. Committed capacity that is consistent yet flexible.
“Customers who have volatility in their supply chain need the ability to quickly flex their fleets up and down, and a good dedicated provider can provide that kind of solution,” explains Downing.
Schneider’s Bozec adds that while “dollars are always important,” the decision to adopt a dedicated strategy often involves other value considerations that don’t show up on an Excel spreadsheet. One example, he notes, is the experience created for the customer. “We will do things like have drivers wear co-branded gear, and the equipment might be co-branded,” he notes. “When you make that delivery, countless times per day, that driver is creating a great experience, [and through that] there is brand equity for the customer that gets built up over time.”
He cites as well two key factors in launching a successful dedicated operation: getting the foundation right through open, frank communication, and effective change management. “We talk change management from the outset, from the C-suite to the loading dock,” Bozec says. “If both organizations don’t get that right, we won’t be as successful as the customer wants us to be and we want to be.”
Greg Orr, executive vice president, North America truckload for TFI International, and president of Joplin, Missouri-based truckload carrier CFI, noticed during March and April customer interest in what he terms “pop-up” fleets. “We’re being asked to provide short-term [60 days or less] committed capacity, deploying assets in certain lanes or between certain regions to address a surge in volume and ensure they’re delivering product to the end customer in a timely fashion,” he notes.
He also is seeing shippers looking to expand current dedicated arrangements. “Customers are coming to us saying, ‘You are handling five of these lanes, would you have interest in these other 10, and if so, could we be more flexible on rates with the additional volume?’” Ultimately, Orr believes carriers have to be more open and able to provide creative solutions that help shippers figure out how to better manage the ebbs and flows in their supply chains.
THE CHOICE TO GO PRIVATE
Why does a shipper look to a private fleet or dedicated operation, and what are the risks?
Ron Baksa is director of fleet procurement for Plano, Texas-based PepsiCo. Between its soft drink and snack products, PepsiCo, by one trucking industry ranking, operates the second-largest private fleet in the U.S. with some 62,400 total vehicles: 14,300 tractors and 48,100 trailers.
The very first question Baksa suggests that those considering a private fleet ask themselves: Are you ready for the commitment in capital, people, systems—can you manage it all? “The combination of people, process, and technology is a huge component,” he says. “You need all three to realize the full benefit.”
PepsiCo’s transportation footprint includes long-haul trucking between plants and distribution centers, and road trucks that deliver product from distribution centers to stores. Its trucks also go to market with products delivered to customer warehouses.
As for the advantages of operating a private fleet, Baksa says a key benefit is having “a cushion against [trucking] market conditions, both operational and financial. You are always able to support the business if you have a significant private fleet,” he says.
Another advantage is the ability to match equipment precisely to product needs. “A common carrier will have a generic 53-foot dry van for all business,” he explains. But that’s not always an efficient vehicle choice. “If you have a very lightweight or cube-sensitive product, you can haul quite a bit more by purchasing a large-cube trailer. Or for heavier product, you can spec more lightweight equipment,” he says.
The challenge is finding—and maintaining—the balance between the rate, the payload, and loaded miles, he adds. “If you can increase your payload [per trailer] by 10%, for every 10 loads you get a free load,” Baksa says, adding:
“The cheapest mile is the one you don’t run.”
A QUESTION OF BALANCE
Bart De Muynck, research vice president, transportation technology, at research firm Gartner, also emphasizes finding the right balance between factors that include priorities, needs, product perishability, velocity, management commitment, and the profile of freight within the shipper’s supply chain. He brings a unique perspective, having previously worked for many years in PepsiCo’s transportation group helping implement technology solutions before joining Gartner, where he serves as a leading transportation technology analyst.
“Companies in general who have private fleets [see] transportation as a very important part of execution,” he notes. “If you have your own fleet, you are guaranteed to execute, you don’t have to worry about [tender] rejections.” Quality factors into it as well, he adds. Shippers invest in private fleets for “high-quality, reliable service” and the guarantee of committed capacity at a relatively fixed cost.
Another benefit is attractiveness to drivers. “Private fleets pay better and have better driver retention,” offering stable runs, regular miles, and consistent home time, De Muynck says. He sees private fleets as ideal for scenarios such as intercompany transport, where truckloads move on regular routes between warehouses, factories and DCs, and/or retail locations, or where you have finished goods going from factory to warehouse, then raw materials moving in backhaul lanes to the factory.
Yet private fleets are not without risk, he warns. Shippers essentially are building and running a trucking operation within the larger enterprise. That means capital investment in rolling stock; building a team with specific transportation management skills, systems, and administrative processes; hiring, managing, and paying drivers; tracking hours of service and ensuring regulatory compliance; and maintaining the fleet.
Not every business is willing to make that leap. Which is where dedicated operations often become a viable solution, De Muynck notes. “Dedicated is almost like a private fleet—assets are dedicated to you,” he explains. “You can optimize routes, but the great thing is you don’t own the asset, you don’t have the upfront cap-ex investment or [responsibility for] hiring additional people. It’s [a good model] for having [secure] capacity, especially when the market tightens up.”
At the end of the day, opines Schneider’s Bozec, the decision on what route to take—private fleet, dedicated, common carrier, or a hybrid combination—comes down to one overriding goal: “It’s what I want to do for my business to win in the market.”
Supply chain risk analytics company Everstream Analytics has launched a product that can quantify the impact of leading climate indicators and project how identified risk will impact customer supply chains.
Expanding upon the weather and climate intelligence Everstream already provides, the new “Climate Risk Scores” tool enables clients to apply eight climate indicator risk projection scores to their facilities and supplier locations to forecast future climate risk and support business continuity.
The tool leverages data from the United Nations’ Intergovernmental Panel on Climate Change (IPCC) to project scores to varying locations using those eight category indicators: tropical cyclone, river flood, sea level rise, heat, fire weather, cold, drought and precipitation.
The Climate Risk Scores capability provides indicator risk projections for key natural disaster and weather risks into 2040, 2050 and 2100, offering several forecast scenarios at each juncture. The proactive planning tool can apply these insights to an organization’s systems via APIs, to directly incorporate climate projections and risk severity levels into your action systems for smarter decisions. Climate Risk scores offer insights into how these new operations may be affected, allowing organizations to make informed decisions and mitigate risks proactively.
“As temperatures and extreme weather events around the world continue to rise, businesses can no longer ignore the impact of climate change on their operations and suppliers,” Jon Davis, Chief Meteorologist at Everstream Analytics, said in a release. “We’ve consulted with the world’s largest brands on the top risk indicators impacting their operations, and we’re thrilled to bring this industry-first capability into Explore to automate access for all our clients. With pathways ranging from low to high impact, this capability further enables organizations to grasp the full spectrum of potential outcomes in real-time, make informed decisions and proactively mitigate risks.”
According to New Orleans-based LongueVue, the “strategic rebranding” brings together the complementary capabilities of these three companies to form a vertically integrated flexible packaging leader with expertise in blown film production, flexographic printing, adhesive laminations, and converting.
“This unified platform enables us to provide our customers with greater flexibility and innovation across all aspects of packaging," Joe Piccione, CEO of Innotex, said in a release. "As we continue to evolve and adapt to the changing needs of the industry, we look forward to delivering exceptional solutions and service."
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Stampin’ Up!’s Riverton, Utah, distribution center
What happens when your warehouse technology upgrade turns into a complete process overhaul? That may sound like a headache to some, but for leaders at paper crafting company Stampin’ Up! it’s been a golden opportunity—especially when it comes to boosting productivity. The Utah-based direct marketing company has increased its average pick rate by more than 70% in the past year and a half. And it’s all due to a warehouse management system (WMS) implementation that opened the door to process changes and new technologies that are speeding its high-velocity, high-SKU (stock-keeping unit) order fulfillment operations.
The bottom line: Stampin’ Up! is filling orders faster than ever before, with less manpower, since it shifted to an easy-to-use voice picking system that makes adapting to seasonal product changes and promotions a piece of cake. Here’s how.
FACING UP TO CHANGE
Stampin’ Up!’s business increased rapidly in 2020, when pandemic-era lockdowns sparked a surge in online orders for its crafting and scrapbooking supplies—everything from rubber stamps to specialty papers, ink, and embellishments needed for home-based projects. At around the same time, company leaders learned that the WMS in use at its main distribution center (DC) in Riverton, Utah, was nearing its end-of-life and would have to be replaced. That process set in motion a series of changes that would upend the way Stampin’ Up! picked items and filled orders, setting the company on a path toward continuous improvement.
“We began a process to replace the WMS, with no intent to do anything else,” explains Rich Bushell, the company’s director of global distribution services. “But when we started to investigate a new WMS, we began to look at the larger picture. We saw problems within our [picking] system. Really, they were problems with our processes.”
Stampin’ Up! had hired global supply chain consulting firm Argon & Co. to help with the WMS selection and implementation, and it was that process that sparked the change. Argon & Co. Partner Steve Mulaik, who worked on the project, says it quickly became clear that Stampin’ Up!’s zone-based pick-and-pass fulfillment process wasn’t working well—primarily because pickers spent a lot of idle time waiting for the next order. Under the old system, which used pick-to-light technology, workers stood in their respective zones and made picks only from their assigned location; when it came time for a pick, the system directed them where to make that pick via indicator lights on storage shelves. The workers placed the picked items directly into shipping boxes that would be passed to the next zone via conveyor.
“The business problem here was that they had a system that didn’t work reliably,” Mulaik explains. “And there were periods when [workers] would have nothing to do. The workload was not balanced.”
This was less than ideal for a DC facing accelerating demand for multi-item orders—a typical Stampin’ Up! order contains 17 to 21 items per box, according to Bushell. In a bid to make the picking process more flexible, Mulaik suggested eliminating the zones altogether and changing the workflow. Ultimately, that would mean replacing the pick-to-light system and revamping the pick-and-pass process with a protocol that would keep workers moving and orders flowing consistently.
“We changed the whole process, building on some academic work from Georgia Tech along with how you communicate with the system,” Mulaik explains. “Together, that has really resulted in the significant change in productivity that they’ve seen.”
RIGHTING THE SHIP
The Riverton DC’s new solution combines voice picking technology with a whole new process known as “bucket brigade” picking. A bucket brigade helps distribute work more evenly among pickers in a DC: Pickers still work in a production-line fashion, picking items into bins or boxes and then sending the bins down the line via conveyor. But rather than stop and wait for the next order to come to them, pickers continue to work by walking up to the next person on the line and taking over that person’s assignment; the worker who is overtaken does the same, creating a process in which pickers are constantly filling orders and no one is picking from the same location.
Stampin’ Up! doesn’t follow the bucket brigade process precisely but has instead developed its own variation the company calls “leapfrog.” Instead of taking the next person’s work, pickers will move up the line to the next open order after completing a task—“leapfrogging” over the other pickers in the line to keep the process moving.
“We’re moving to the work,” Bushell explains. “If your boxes are full and you push them [down the line], you just move to the open work. The idea is that it takes the zones away; you move to where the next pick is.”
The voice piece increases the operation’s flexibility and directs the leapfrog process. Voice-directed picking allows pickers to listen to commands and respond verbally via a headset and handheld device. All commands filter through the headset, freeing the worker’s eyes and hands for picking tasks. Stampin’ Up! uses voice technology from AccuSpeechMobile with a combination of company-issued Android devices and Bluetooth headsets, although employees can use their own Bluetooth headsets or earbuds if they wish.
Mulaik and Bushell say the simplicity of the AccuSpeechMobile system was a game-changer for this project. The device-based system requires no voice server or middleware and no changes to a customer’s back-end systems in order to operate. It uses “screen scrape” technology, a process that allows the collection of large volumes of data quickly. Essentially, the program translates textual information from the device into audible commands telling associates what to pick. Workers then respond verbally, confirming the pick.
“AccuSpeech takes what the [WMS] says and then says it in your ear,” Bushell explains. “The key to the device is having all the data needed to make the pick shown on the screen. However, the picker should never—or rarely—need to look at the screen [because] the voice tells them the info and the commands are set up to repeat if prompted. This helps increase speed.
“The voice piece really ties everything together and makes our system more efficient.”
And about that system: Stampin’ Up! chose a WMS from technology provider QSSI, which directs all the work in the DC. And the conveyor systems were updated with new equipment and controls—from ABCO Systems and JR Controls—to keep all those orders moving down the line. The company also adopted automated labeling technology and overhauled its slotting procedure—the process of determining the most efficient storage location for its various items—as part of the project.
MISSION ACCOMPLISHED
Productivity improvement in the DC has been the biggest benefit of the project, which was officially completed in the spring of 2023 but continues to bear fruit. Prior to the change, Stampin’ Up! workers averaged 160 picks per hour, per person. That number rose to more than 200 picks per hour within the first few months, according to Bushell, and was up to 276 picks per hour as of this past August—a more than 70% increase.
“We’ve seen some really good gains,” Bushell says, adding that the company has reduced its reliance on both temporary and full-time staff as well, the latter mainly through attrition. “Overall, we’re 20% to 25% down on our labor based on the change …. And it’s because we’re keeping people busy.”
Quality has stayed on par as well, something Bushell says concerned him when switching from the DC’s previous pick-to-light technology.
“You have very good quality with pick-to-light, so we [worried] about opening the door to errors with pick-to-voice because a human is confirming each pick,” he says. “But we average about one error per 3,300 picks. So the quality is really good.”
On top of all that, Bushell says employees are “really happy” with the new system. One reason is that the voice system is easy to learn—so easy, anyone can do it. Stampin’ Up! runs frequent promotions and special offers that create mini spikes in business throughout the year; the new system makes it easy to get the required temporary help up to speed quickly or recruit staff members from other departments to accommodate those spikes.
“We [allocate] three days of training for voice, but it’s really about an hour,” Bushell says, adding that some of the employees from other departments simply enjoy the change of pace and the exercise of working on the “leapfrog” bucket brigade. “I have people that sign up every day to come pick.”
Not only has Stampin’ Up! reduced downtime and expedited the picking of its signature rubber stamps, paper, and crafting supplies, but it’s also blazing a trail in fulfillment that its business partners say could serve as a model for other companies looking to crank up productivity in the DC.
“There are a lot of [companies] that have pick-and-pass systems today, and while those pick-and-pass systems look like they are efficient, those companies may not realize that people are only picking 70% of the time,” Mulaik says. “This is a way to reduce that inactivity significantly.
“If you can get 20% of your productivity back—that’s a big number.”
With its new AutoStore automated storage and retrieval (AS/RS) system, Toyota Material Handling Inc.’s parts distribution center, located at its U.S. headquarters campus in Columbus, Indiana, will be able to store more forklift and other parts and move them more quickly. The new system represents a major step toward achieving TMH’s goal of next-day parts delivery to 98% of its customers in the U.S. and Canada by 2030, said TMH North America President and CEO Brett Wood at the launch event on October 28. The upgrade to the DC was designed, built, and installed through a close collaboration between TMH, AutoStore, and Bastian Solutions, the Toyota-owned material handling automation designer and systems integrator that is a cornerstone of the forklift maker’s Toyota Automated Logistics business unit. The AS/RS is Bastian’s 100th AutoStore installation in North America.
TMH’s AutoStore system deploys 28 energy-efficient robotic shuttles to retrieve and deliver totes from within a vertical storage grid. To expedite processing, artificial intelligence (AI)-enhanced software determines optimal storage locations based on whether parts are high- or low-demand items. The shuttles, each independently controlled and selected based on shortest distance to the stored tote, swiftly deliver the ordered parts to four picking ports. Each port can process up to 175 totes per hour; the company’s initial goal is 150 totes per hour, with room to grow. The AS/RS also eliminates the need for order pickers to walk up to 10 miles per day, saving time, boosting picking accuracy, and improving ergonomics for associates.
The upgrades, which also include a Kardex vertical lift module for parts that are too large for the AS/RS and a spiral conveyor, will more than triple storage capacity, from 40,000 to 128,000 storage positions, making it possible for TMH to increase its parts inventory. Currently the DC stores some 55,000 stock-keeping units (SKUs) and ships an average of $1 million worth of parts per day, reaching 80% of customers by two-day ground delivery. A Sparck Technologies CVP Impack fit-to-size packaging machine speeds packing and shipping and is expected to save up to 20% on the cost of packing materials.
Distribution, manufacturing expansion on the agenda
The Columbus parts DC currently serves all of the U.S. and Canada; inventory consists mostly of Toyota’s own parts as well as some parts for Bastian Solutions and forklift maker The Raymond Corp., which is part of TMH North America. To meet the company’s goal of next-day delivery to virtually all parts customers, TMH is exploring establishing up to five additional parts DCs. All will be TMH-designed, owned, and operated, with varying levels of automation to meet specific needs, said Bret Bruin, vice president, aftermarket sales and operations, in an interview.
Parts distribution is not the only area where TMH is investing in expanded capacity. With demand for electric forklifts continuing to rise, the company recently broke ground for a new factory on the expansive Columbus campus that will benefit both Toyota and Raymond. The two OEMs—which currently have only 5% overlap among their customers—already manufacture certain forklift models and parts for each other, said Wood in an interview. Slated to open in 2026, the $100 million, 295,000-square-foot factory will make electric-powered forklifts. The lineup will include stand-up rider trucks, currently manufactured for both brands by Raymond in Greene, New York. Moving production to Columbus, Wood said, will not only help both OEMs keep up with fast-growing demand for those models, but it will also free up space and personnel in Raymond’s factory to increase production of orderpickers and reach trucks, which it produces for both brands. “We want to build the right trucks in the right place,” Wood said.
Editor's note:This article was revised on November 4 to correct the types of equipment produced in Raymond's factory.
“The latest data continues to show some positive developments for the freight market. However, there remain sequential declines nationwide, and in most regions,” Bobby Holland, U.S. Bank director of freight business analytics, said in a release. “Over the last two quarters, volume and spend contractions have lessened, but we’re waiting for clear evidence that the market has reached the bottom.”
By the numbers, shipments were down 1.9% compared to the previous quarter while spending dropped 1.4%. This was the ninth consecutive quarterly decrease in volume, but the smallest drop in more than a year.
Truck freight conditions varied greatly by region in the third quarter. In the West, spending was up 4.4% over the previous quarter and volume increased 1.1%. Meanwhile, in the Southeast spending declined 3.3% and shipments were down 3.0%.
“It’s a positive sign that spending contracted less than shipments. With diesel fuel prices lower, the fact that pricing didn’t erode more tells me the market is getting healthier,” Bob Costello, senior vice president and chief economist at the American Trucking Associations (ATA), said in the release.
The U.S. Bank Freight Payment Index measures quantitative changes in freight shipments and spend activity based on data from transactions processed through U.S. Bank Freight Payment, which processes more than $42 billion in freight payments annually for shippers and carriers across the U.S. The Index insights are provided to U.S. Bank customers to help them make business decisions and discover new opportunities.