Parcel carriers, shippers steer into choppy waters as a perfect storm of challenges approaches
Summer is shaping up to be one for the history books as the market contends with UPS’s labor negotiations, FedEx’s restructuring, downshifting consumer spending, and slackening parcel demand.
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.
As the parcel express market heads into summer, a perfect storm of carrier challenges, market shifts, an unsettled economy, and weakening demand is threatening to upend the best-laid plans of shippers—just as supply chains are beginning to normalize after two years of pandemic-induced turmoil.
Among the challenges:
A massive restructuring at FedEx designed to cut costs, consolidate ground and express parcel network operations into a new organizational structure called “One FedEx,” and ultimately shutter and combine some 100 locations.
Slowing e-commerce volumes as consumers become more cautious, shift spending from goods to services, and return to shopping in stores.
Shippers dealing with stubbornly high rates as well as a rising tide of parcel and package surcharges and fees.
And last, but certainly not least, an expiring contract and upcoming July deadline as the Teamsters Union and United Parcel Service negotiate a new labor agreement impacting some 330,000 workers and about 20 million packages a day.
NAVIGATING THE NOISE
John Janson has seen this movie before. A 25-plus year veteran of logistics and transportation, he remembers the last UPS strike, in 1997, and the disruption, however temporary, that rippled through not just the parcel markets but the LTL (less-than-truckload) and other trucking and delivery sectors as well. He recalls that back then, carriers were so swamped they were drafting sales and administrative personnel to make deliveries. “It was a crazy time.”
As vice president of global logistics for branded apparel and promotional products distributor SanMar, he’s on the front lines, with his team responsible for managing some 10 distribution centers that ship over 100,000 packages every evening. “Nobody can afford a UPS strike,” he says. “UPS ships some 20 million packages a day. There is no home for those.”
Janson believes the negotiations will be “very noisy and contentious” and will go very late. “The Teamsters president has come out swinging. His goal will be to get a great contract for his members. It will not be settled early, but it will be settled.”
“It’s going to be a crazy summer around the parcel industry,” he says.
Dan Johnston, chief executive officer and co-founder of Workstep, which provides software that helps companies measure and understand worker sentiment and reasons for turnover, thinks the eventual contract the Teamsters get from UPS will be a big signal for the rest of the market.
“If the union gets what looks like a win for its members, that could certainly [be a catalyst] for more organizing activity.”
Negotiations for the next round of union contracts at LTL operators are coming up, he notes. Union wins at Amazon and Starbucks have added momentum to union organizing efforts. These have been more aggressive organizing activities, which is “something that 3PLs and warehouse operators need to keep top of mind,” he observes.
Johnston argues that since the last half of 2020, a tight labor market for supply chain workers has given labor more leverage, as evidenced by rising pay rates for material handlers, truck drivers, and other supply chain workers.
“Companies are doing all they can to keep employees and provide competitive wages,” he notes, adding that even with softening demand for freight services and slower growth of e-commerce, experienced supply chain workers remain in high demand. Right now, “labor is in the driver’s seat in a way we hadn’t seen in supply chain prior to the last three years.”
MAKING PROGRESS
UPS Chief Executive Officer Carol Tomé, in UPS’s recent first-quarter earnings conference call, noted that “good progress has been made on many of our local supplemental agreements” with the Teamsters. “Together we’ve set up five subcommittees to take on key areas of the contract, which enables us to move faster.”
She echoed the view of SanMar’s Janson, commenting that “while we expect to hear a great deal of noise during the negotiation, I remain confident that a win-win-win contract is very achievable, and that UPS and the Teamsters will reach agreement by the end of July.”
The effects of a tepid economy and softer overall demand for package delivery services did show up in UPS’s first-quarter 2023 results. Average daily volume was down 5.4% year over year. A shift in product mix from air to ground that the company saw in the fourth quarter continued into the first quarter “as customers made cost tradeoffs and took advantage of the speed improvements we made in our ground network,” said Brian Newman, UPS’s executive vice president and chief financial officer.
Nevertheless, the company is optimistic about the year. “We have confidence that the volume will come back [after] the summer, related to customer conversations and some of the macro, which we think will trough in the middle part of the year,” Newman said in the call. The company continues to invest for growth, sticking with a $5.3 billion capital expenditure plan for 2023 to support its strategy and capture growth coming out of the current cycle.
MEANWHILE, AT FEDEX
In April, FedEx dropped a bombshell with its announcement of plans to consolidate operating companies. The phased transition, which the company says it expects to be fully implemented in June 2024, will bring together FedEx Express, FedEx Ground, FedEx Services, and other operating units into a single operating company under the FedEx brand, explained President and CEO Raj Subramaniam.
“Our new structure will provide a distinct focus on air and international volume, while facilitating a more holistic approach to how we move packages on the ground, utilizing both FedEx employees and contracted service providers,” he said.
Jenny Robertson, FedEx’s senior vice president of integrated marketing and communications, emphasized that the company is being deliberate and methodical in the effort, moving to a streamlined organization that will “help our customers compete through a fully integrated ground and air network.”
The plan will help the company execute an initiative it calls Network 2.0, which involves integrating its networks through facility consolidations and reducing some redundancy of routes, she noted. Under the plan, the company has committed to closing at least 100 facilities by 2027, although that number could change.
And while FedEx says it has always offered a full portfolio of services to customers, “there are some elements that can be streamlined with this change, such as billing, invoicing, who to call with an issue,” she explained. With the integration and the rollout of One FedEx, “customers … can look forward to a more seamless experience and a more flexible, efficient organization.”
She noted that FedEx had begun implementing some strategic consolidation initiatives before the pandemic, such as optimizing last-mile residential deliveries where FedEx Express contracted with FedEx Ground for the transport and delivery of certain shipments, but then the pandemic hit and e-commerce-driven package volumes went through the roof.
“We were focused on handling the volume spikes during that period,” she recalled. “Now as we come out of that, we have an opportunity with innovations in AI and data to rethink our operating structure,” she said.
Robertson emphasized that for FedEx as it emerges into its new, leaner form, “e-commerce and residential delivery are still the No. 1 area for growth. We see a lot of opportunity to realign our network to address and capture that growth.”
SURCHARGES CREEP UP AS MARGINS HOLD
Package volumes have clearly slowed and demand remains soft, but that hasn’t prevented parcel carriers from implementing tactics to protect yield and expand revenue per shipment, noted Micheal McDonagh, president of parcel for AFS Logistics, an audit and cost management specialist that manages over $4 billion in parcel spend annually for about 900 customers. He noted that in FedEx’s most recent earnings call, the company reported per-package revenue increased 11%, even with decreased volume.
“It’s interesting what is happening to yield” as well as stubbornly resilient parcel rates, he notes. Among the factors (or culprits if you are a shipper): fuel surcharges that go up quickly, but when fuel prices decline, don’t drop as fast; surcharges that were once instituted for weeks, but now extend for months or a full year; and one especially “under the radar” item—late fees charged by carriers.
“[Carrier] payment terms used to be 30 days; now they want payment in seven to 15 days,” he explains. “So getting everything turned around and paid that much quicker is a much bigger ask when you have less time to do it.” And with some carriers, the late fee has increased from 6% to 8%.
Then there are what used to be “peak” surcharges. In 2018, McDonagh recalls, peak surcharges started around Black Friday and ended around Dec. 23.
“Now, post Covid, peak charges start in October and extend to January. And in some cases, they never go away.” What once had a time limit, in some cases “is now indefinite” and charged all year. Large and oversized shipments are particularly vulnerable.
Another area is “remote” delivery surcharges, where the carrier charges an extra fee for rural or extended-delivery areas. “Delivery area surcharges extended during peak were $7.15. Now they are $13.25 for specific ZIP codes, and they don’t go away. No added service but an extra charge. It’s a great way [for the carrier] to increase revenue without adding cost,” he says.
As for how shippers can best protect themselves, McDonagh counsels customers to be strategic yet careful about spreading out their volumes among multiple carriers.
“Our recommendation is to have at least two carriers, but be careful,” he emphasizes. “A lot of discounts are based on revenue spend. The more you spend [with the carrier], the higher the discount. When dividing your volume among carriers, be sensitive with spend levels. If you fall down a tier, you lose the discount, and that could negate the savings you expected.”
He notes as well that with any backup carrier, it’s critical to thoroughly test it and run shipments through its network ahead of time to make sure your transportation management system (TMS) and the carrier’s systems work well together.
McDonagh suggests further caution in cases where shippers might consider temporarily moving some parcel volume from UPS to another parcel provider as a hedge against labor disruption. While he thinks the two parties will come to an agreement and avoid a strike, “FedEx and the regional parcel carriers don’t want to mess up their networks with a few days of volume that they will never see again after a strike is over.”
He warns that unless you are committing that freight to the carrier for the long term and make it a part of your parcel solution, either the carrier won’t take it short term or it will be priced so high as to blow your budget.
WHAT ABOUT AMAZON?
Amazon has built out an extensive network to provide parcel delivery of goods bought through Amazon. With all the turmoil currently roiling the parcel market, is now the time for Amazon to open its network to non-Amazon packages?
Jess Dankert, vice president of supply chain for the retail trade group the Retail Industry Leaders Association (RILA), says she “would not be surprised” if that happened sooner rather than later. And while she stresses that RILA is not in any conversations about such a plan, she believes it would complement Amazon’s current operations and the moves of other big retailers, such as Target and Walmart, who have established some dedicated last-mile delivery services that are available to other retailers.
One issue is inefficiencies in the current parcel market, and how better data sharing and interoperability could promote competition and improve service. “For the parcel market generally, more competition is an interesting ingredient to add,” she says. “It remains to be seen how that is going to shake out.”
In the meantime, the past three years have seen dramatic changes in how RILA members stock, fulfill, and ship goods—driven by the surge in e-commerce and emergence of new technologies. “The supply chains our members have built were made to be flexible, responsive, and able to manage through disruption,” she notes. “When it comes to e-commerce, retailers are managing cost to serve.”
She adds that for some retailers, up to 80% of fulfillment may be done from retail store locations, either with parcel carriers handling the last mile or through the consumer BOPIS (buy online/pick up in store) model. For others, e-commerce package fulfillment is primarily centralized at DCs.
Each retailer has to figure out what makes the most sense for the customer and the product line, she adds. At the end of the day, “it’s a balance between customer expectation, the product itself, the resources required and their cost, and the need for speed—or not,” she says.
“There are clear benefits to having fulfillment start closer to the consumer, with dedicated providers doing the last mile, but it’s a calculation that’s done every day as retailers work to meet their cost and service goals and drive a superior customer experience.”
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]."