When the pandemic hit, e-commerce exploded, flooding parcel networks with record volumes that have yet to ease. With carrier capacity already maxed out, what can shippers expect for the holiday peak season?
Gary Frantz is a contributing editor for DC Velocity and its sister publication, Supply Chain Xchange. He is 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.
Last March and April, parcel express carriers got a temporary reprieve. Volumes declined as the pandemic closed businesses, consumers sheltered in place, and those who could started working from home. Traditional business-to-business supply chain channels in which parcel shipments flowed from suppliers to retailers dried up. Canceled sailings sank ship calls into U.S. ports, driving double-digit declines in imports.
Yet consumers still had pantries to fill and refrigerators to stock, toilet paper and other essential goods to buy, prescriptions to refill, and back yards to be spruced up—not to mention a variety of home-improvement projects on their to-do lists.
And with that, consumers went online with a vengeance. Parcel carriers had barely caught their breath when May, June, and July saw e-commerce explode, residential parcel deliveries ramp up to record levels, network capacity quickly become constrained, and an early, pandemic-induced peak season emerge through the summer and into the fall.
“It is the best [market for parcel carriers] I have seen in 30 years,” observes Satish Jindel, president of Pittsburgh, Pennsylvania-based ShipMatrix Inc., a subsidiary of Jindel’s SJ Consulting Group that helps shippers leverage shipping technology and data to reduce parcel-shipping costs and improve service. “It’s firing on all cylinders. [Parcel carriers] can tell the customer ‘Take it or leave it. … I just don’t have the capacity to handle [more volume].’”
The pandemic-induced e-commerce surge “has pushed carrier capacity to the brink,” says Meg Duncan, director of strategic sourcing for third-party logistics service provider (3PL) Koch Logistics, based in Minneapolis. “And it’s not letting up.” She notes that one of her parcel carriers was hiring 500 drivers a week in the Los Angeles market just to keep up. “In certain markets, [parcel carriers] are just under water. It’s kind of like the Wild West.”
Duncan’s company provides businesses with logistics planning and transportation management services supporting store operations, such as buildouts and remodels. When the pandemic hit, a lot of that work was put on hold. As businesses brought projects back online, the timing coincided with the surge in consumer e-commerce activity. The result was an almost immediate capacity crisis in the parcel and even traditional freight markets.
RISING DEMAND PUSHES UP COSTS
And it’s all exacerbated by Amazon’s continued emphasis on free shipping to Prime customers. “Freight is not free,” observes Duncan, who adds that consumers should find a balance between online ordering and keeping local businesses a viable choice. “Once we get through this, do people go back to their traditional shopping patterns with local stores?” she asks. “If not, what does that mean for freight and shipping [capacity]?”
Amazon certainly is not standing still and is taking matters more and more into its own hands to ensure it has sufficient delivery capacity to prevent delays. It’s been reported that the company is initially establishing some 1,000 new, smaller delivery hubs in cities across the nation, designed to cut the last-mile “stem time” (the time that elapses from when a driver leaves the terminal until the driver makes the first delivery) by placing hubs closer to suburban delivery points. Those hubs could grow to as many as 1,500. The strategy also provides more support infrastructure for Amazon’s continued push into same-day delivery for Prime customers.
One fact is unequivocal: Parcel shipping costs are going up. UPS, FedEx, and the U.S. Postal Service all have announced rate increases and early-season, pandemic-induced surcharges—which took effect during the summer ahead of the traditional peak season. In some cases, additional surcharges for large-volume shippers have been imposed as well. And some markets have become so capacity constrained that the major parcel carriers are not taking new business or accepting additional volume that’s outside of capacity contractually promised to a shipper.
It’s a convergence of surging pandemic-induced e-commerce ordering coupled with traditional peak season volumes, collectively driving a “super peak” of parcel volume and costs. And still to come is the impact of already-announced Jan. 1 rate increases.
BRACING FOR THE “SUPER PEAK”
The industry is navigating through unprecedented times, notes Ryan Kelly, vice president of global e-commerce marketing for FedEx. “The growth we expected … over the next several years” has happened in a matter of months, he says of the surge in e-commerce–driven parcels. “We’ve been seeing peak-level volumes since March, and we expect that to continue” through the peak holiday season. “It will be unlike any peak we have seen in our company’s history,” he says.
Among the initiatives Kelly says FedEx has implemented to help manage the surge and maintain service consistency has been continued investment in technology at multiple levels, going to seven-day-a-week residential deliveries, building out and optimizing capacity in FedEx Ground’s network and field operations, and having FedEx Ground do last-mile day-definite delivery of certain residential FedEx Express packages.
It’s a time when shippers are challenged as never before to plan effectively, negotiate smartly, secure capacity in advance, and do all they can to mitigate an ever-increasing shipping-cost hit to the bottom line—while making sure goods get delivered.
“My advice to shippers is to leverage a 3PL that can position your products in multiple markets and ensure your inventory is accessible from multiple ship points,” recommends Ryan Singerline, senior director of customer logistics for Miami-based Ryder. Singerline adds that, with e-commerce fulfillment centers in Pennsylvania, Texas, and California, Ryder has “the ability to reach 99% of the U.S. within two days.”
MOVING TARGET
At the same time, it’s becoming clear that the market itself is in flux. A survey done by UPS subsidiary Ware2Go helps to illustrate the evolving market. The study, which was conducted among 250 merchants in August, found that 77% had changed their selling strategies in response to Covid-19, with 35% launching an online store for the first time. That shift to direct-to-consumer e-commerce channels also had repercussions for respondents’ order fulfillment operations, leading many to expand their delivery options, the study showed. Among the findings:
25% changed their mix and started selling new products
22% opened a new sales channel
56% saw an increase in new customers over the past six months
56% began offering no-contact delivery
34% added two-day shipping guarantees.
“The current situation requires merchants to prepare for a holiday season where historical trends are not as relevant,” Steve Denton, Ware2Go’s chief executive officer, said in a statement announcing the survey results. “Today’s market … requires merchants to leverage a flexible supply chain as a strategic asset for commerce.”
Josh Dinneen is senior vice president at Vienna, Virginia-based LaserShip, which provides primarily e-commerce residential parcel delivery services, operating a network of 60 service locations and four hubs covering 20 states across the Eastern Seaboard and through the Midwest. He notes that an interesting finding from a LaserShip survey of 1,000 consumers was the rapid uptake of e-commerce among baby boomers, nearly half (47%) of whom plan to continue their online buying after the pandemic. Dinneen cites that as a clear indication that the move from “offline to online channels certainly will stay. It’s sustainable,” he says.
Dinneen cautions, however, that “the holiday season will be tough … nothing like we have ever seen before.” He believes the current capacity constraints in the parcel market are enduring and will take 12 months to flush out.
Some shippers, he says, didn’t anticipate the capacity crunch and are now scrambling for capacity at any cost. “I had a good-sized brick-and-mortar retailer contact me [recently],” he recalls. “He asked if we had capacity for November and December. Unfortunately, my response was ‘Sorry, we do not.’ He then asked, ‘Was there any amount of money that would change that—tell me what I have to pay.’ He was dead serious.” Dinneen has been telling new customers that they can reserve now, but LaserShip will not be able to bring them on board until January.
BEYOND PARCEL CARRIERS
The capacity crunch is driving retailers to explore alternatives to traditional parcel carriers. Some retailers are more aggressively promoting their BOPIS (buy online/pick up in store) services as a kind of self-serve delivery. That’s an option for consumers who live or work in close proximity to a brick-and-mortar store, where the order is filled locally and staged for pickup. Retailers are encouraging this by offering discounts on future purchases.
It’s also been a boon to “crowdsourced” delivery firms—those who sign up people part-time to make parcel deliveries. One of the more established players in this field is same-day delivery provider Roadie, based in Atlanta. Roadie’s “on the way” model taps drivers already on the road in their personal vehicles and diverts them to a nearby store for pickup. The drivers typically deliver orders within hours.
Roadie’s use by retailers has surged with the pandemic. From February through April, Roadie’s large retail customers saw increases in weekly same-day deliveries ranging from 151% to 1,456%. In that same period, the number of new store locations launching Roadie’s same-day service went up by anywhere from 110% to 365%. One client, Tractor Supply Co., in 30 days went from piloting Roadie at 400 stores to a full nationwide rollout across the home-improvement retailer’s entire network of 1,863 stores.
“The environment just gets more and more unusual,” notes Marc Gorlin, chief executive officer of Roadie, which counts among its customers The Home Depot, Advance Auto Parts, Nothing Bundt Cakes, and Delta Airlines. “As demand rises, parcel networks have to tack on surcharges and price hikes to prioritize demand. It’s a story that plays out every peak season, and the pandemic brought it on early this year.”
As long as shippers look to large parcel carriers’ fixed-asset solution, it’s a scenario that inevitably will repeat itself, he believes. Roadie’s “on-the-way” driver fleet, by contrast, “flexes dynamically based on the needs of the customer. By tapping into resources already on the road, we embrace a just-in-time delivery model that has the same or better reliability and speed than fixed-asset networks,” Gorlin explains.
The strategies that enabled businesses to stay above water during the pandemic “are going to strengthen and position them for success” through 2020 and into the new year, he believes. “Consumers are a long way from returning to their previous shopping habits, if they ever do,” Gorlin concludes. “Once you know how easy it is to get something delivered, why risk the store?”
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]."