The new parcel reality: Record volumes, tight capacity, higher costs, inconsistent service
Parcel carriers weathered a remarkable stretch of challenges over the past year, as a deluge of pandemic-influenced online shipments flooded networks, hammered service, and blew out shipper budgets. The struggles continue, so what comes next?
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.
“It’s a great time to be in the parcel business,” says Dick Metzler, chief executive officer of regional parcel carrier LSO, which operates primarily in Texas and Oklahoma, home to some 35 million consumers. Metzler’s upbeat assessment will come as no surprise to anyone who follows the industry. Parcel volumes, supercharged by the pandemic and e-commerce–happy stay-at-home consumers, have sent revenues soaring for parcel carriers. LSO saw volumes double in 2020, Metzler says, generating $65 million in revenues last year and tracking toward over $100 million for 2021.
He’s not alone. Virtually all parcel carriers have reported record numbers for 2021’s first quarter. Those results illustrate the impact of network-busting volumes but also the ongoing struggles as parcel carriers try to bring their networks back into balance after 2020’s Covid-driven surge—and battle a continuing crush of e-commerce traffic.
Parcel behemoth UPS in the first quarter this year saw average daily volume increase 12.8% to 20.4 million packages per day. Average daily volume for the business-to-consumer segment, which includes e-commerce–fueled residential deliveries, surged 77.6%. UPS estimates that online sales this year will rise 12.7%, following growth of 24.7% in 2020.
THE PARTY’S JUST STARTING
And by some reckoning, the party’s just starting.
Pre-Covid, parcel giant FedEx projected that the U.S. domestic package market would hit 100 million packages per day by 2026. That growth milestone is now expected to arrive four years earlier—in 2022, with 86% of that growth expected to come from e-commerce.
“The rapid onset of Covid-19 … has forever changed e-commerce,” says Ryan Kelly, FedEx’s vice president, e-commerce and alliance marketing. “Shoppers were pushed online overnight, and in that instant, everyone from larger industry retailers to small mom-and-pop businesses had to revamp their business models.”
As evidence of shifting consumer buying behavior, Kelly cited a recent Global Shopping Index report published by Salesforce that found the number of unique digital shoppers rose 40% year over year. Another FedEx-commissioned consumer study, released in March, found that 70% of shoppers are buying from more online retailers today than they did a year ago. “The speed of change across every industry has been unlike anything we’ve ever seen,” Kelly observed.
STRAINED NETWORKS, SERVICE DELAYS
The rapid growth in parcel volumes has strained capacity and impacted service levels, driving supply chain managers to distraction. At the height of last year’s peak season, some shippers found the capacity previously committed to them by carriers either cut or capped. In some instances, shippers had to pay additional surcharges if their package volumes exceeded contractual commitments, and for shipments above certain weights or dimensions.
And while the first quarter saw surcharges moderate and service start to improve, parcel shippers remained frustrated. LSO’s Metzler shared one conversation he had late last year with a large account that had been a loyal 30-year customer of one of the “Big 2” parcel carriers. “They sent in a guy who told them, ‘Look, you have to shed 30% of your volume in 30 days,’” he recalled.
Shippers have long memories, and whether the market is tight or loose, “I don’t care how far technology evolves, relationships matter,” Metzler says. “If you burn someone, you [might] have to wait until the guy retires to get back in the door.”
Not to be left by the side of the road, other regional parcel carriers also are experiencing the surge effect.
LaserShip, a regional parcel carrier that covers 20 states in the Midwest and Eastern U.S., a market of over 100 million consumers, saw its business in 2020 grow 58.2% to $715 million, according to data from SJ Consulting Group, which ranked it the fastest-growing trucking operator in the U.S. last year. LaserShip deploys a network of more than 60 depots supported by four sort hubs and has some 5,000 drivers making daily parcel deliveries.
Similarly, according to SJ Consulting data, OnTrac, a Western regional parcel carrier, grew revenues 34.6% to $832 million last year, landing as 2020’s second fastest-growing U.S. trucking operator. OnTrac, which serves eight Western states that collectively have some 66 million residents, operates 34 pickup and delivery facilities, including six that do double-duty as sort hubs.
NO LETUP
The market’s growth shows no signs of letting up anytime soon. And that’s keeping up the pressure on capacity. “They are beating down our door,” Mark Magill, OnTrac’s vice president of business development, says of interested customers looking for reliable capacity and cost-effective service. “Not only do we have peak numbers already, but the number of larger shippers seeking capacity from us continues to grow.”
The effect of e-commerce has been daunting, says Magill, who notes that 86% of OnTrac’s deliveries are to residential addresses. Long-time e-commerce shoppers are buying more, while older shoppers—those from the baby boomer generation who once shied away from e-commerce—have become avid users. During Covid, “they had no choice but to buy online,” Magill notes. “Once they found out how easy [online shopping] was, why go back to the store and risk getting Covid?”
OnTrac suspended new business at the end of last year, but started taking new customer requests again in the first quarter. Looking ahead to a market facing persistent capacity issues, Magill advises shippers to start planning now to secure capacity for the coming peak season. Those who delay could find their parcels sitting on the dock.
In response to the capacity crunch, supply chain managers are increasingly looking to diversify, carving out portions of their parcel business to give to regional carriers where there is a fit and capacity—and finding creative alternatives to “zone skip.”
Magill has seen instances of East Coast shippers (often those who lack a West Coast distribution center) consolidating thousands of West Coast-destined parcel shipments into a 53-foot dry-van trailer, linehauling them with a two-driver truckload team, and then injecting those shipments into OnTrac’s main Reno, Nevada, sort center. From Reno, OnTrac says it provides next-day service as far south as the Mexican border and north to the Canadian border.
The reason driving the alternative strategy: volume restrictions with national parcel carriers that limited pickups in certain areas and delayed cross-country service. Magill has even seen consolidated parcel loads coming into Reno via intermodal rail.
THE FREE-SHIPPING ADDICTION
As for those on the receiving end, consumers annoyed by parcel delays and higher costs “should not be mad at anyone except themselves for their inability to manage their addiction to [want it now] consumption …,” remarks Satish Jindel, president of SJ Consulting Group and its data analytics subsidiary, ShipMatrix. Thanks to Amazon, consumers have been lulled into the perception that e-commerce orders come with “free” shipping. “It’s not free; it’s built into the price of what you are ordering,” says Jindel.
Make no mistake, retailers and online shippers are paying the parcel carriers for their services, he emphasizes. If shippers are upset at surging parcel costs, “they should look in the mirror. They are responsible … because they failed to prepare for the conversion [of commerce] from store to online. And it’s here to stay.” He projects online growth to continue at a 15% to 16% clip annually. “If you don’t need to touch, feel, or see it, why go through the difficulty of driving to the store? And then finding out [what you want] is not on the shelf?” he says.
However, Jindel adds, there is a silver lining for carriers: more density per route and higher productivity. “As density increases, it will reduce the cost of [business-to-consumer] deliveries,” he says. “Instead of the driver making 10 stops an hour, now [because of more e-commerce deliveries in close proximity], he’s making 12 or 14 and that lowers the cost per stop,” he notes, adding that parcel carriers may choose to share a portion of the savings to grow profitable market share faster.
TECH RIDES TO THE RESCUE
Then there is the technology component, which is evolving at an unprecedented pace and scale.
The dramatic growth of parcel volumes, and the increasing complexity and breadth of delivery networks, has only heightened the need for more advanced, flexible, and adaptable multicarrier parcel management technologies, says Bart De Muynck, VP analyst for transportation technology with research firm Gartner Inc.
The goal: faster deliveries over shorter distances at the lowest possible cost.
It’s no longer a shipment originating at one DC and being sent to one address. “How do you route and price things when you have alternative pickup and delivery points?” he notes.
Today’s omnichannel networks require parcel management platforms that can certify and manage multiple carriers. They also must evaluate multiple alternative routings and then select the best one to accommodate pickups that might originate at multiple points, such as a DC, a local brick-and-mortar store, a temporary “popup” storefront, or a third-party service provider.
Then the delivery could be to a job site, a business or residential address, a retail store (where the consumer picks up the online order), or a locker at, say, the local Safeway store. And lastly, the system has to determine the best carrier for the desired service, whether it’s same-day, next-day, or later. That means deploying a wider base of resources, from less-than-truckload (LTL) carriers to UPS and FedEx to regional parcel carriers and even crowdsourced same-day networks like Roadie, De Muynck says.
“What people are looking for is analytics and more intelligence in their systems,” De Muynck says, noting that the highest demand is for real-time visibility, distributed order management, and multicarrier parcel management—all connected and supportive of overall goals for lowest-cost, best-service delivery.
“How do you make sure you [accurately] calculate all that?” he asks. “Today’s distributed technologies are far more sophisticated than the transportation management systems of the past. These platforms and their capabilities are a must-have and are critical to making the right decision with the right resources to meet the fulfillment expectation of each consumer.”
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]."