Maritime operators, ports, take a step back as slack demand, destocking depress volumes and rates
The maritime industry breathed a sigh of relief as West Coast ports inked a labor agreement. The next challenges: the effects of climate change, a tepid global economy, new environmental regs, and a looming capacity glut.
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.
It’s been an interesting summer for port and maritime operators. A potential strike among West Coast longshore workers appears to have been averted as management and labor hammered out an 11th hour agreement, which now goes to members for ratification. Drought conditions impacting water levels—and ship passages—through the Panama Canal have moderated, forestalling potential delays and more serious restrictions. And while loose capacity, slack demand, and weak shipping volumes have forced ocean containership operators to park some ships and slow-steam others, some industry watchers believe the market has bottomed out and is primed for a rebound.
“We believe that the container shipping downturn bottomed out in February,” says Bryan Brandes, the Port of Oakland’s maritime director. “Oakland cargo volumes have been on a steady increase for three consecutive months since February.”
At the Port of Long Beach, “the trajectory has been very good,” observes Executive Director Mario Cordero. “Volumes for the month of May, at 158,000 TEUs [20-foot equivalent units], were the highest since August 2022” and represented a 15% increase over April 2023. “We expect by the end of the year for the San Pedro Bay complex to have [more] TEU volume than any other gateway,” Cordero says, adding that the Long Beach/Los Angeles port complex is the nation’s largest container gateway.
The Port of Virginia sees “ocean freight moving in the direction of returning to normal,” says port spokesman Joe Harris, who noted that the Covid-driven surges were an anomaly and that “going forward, volumes are going to be impacted by more traditional factors like inflation, consumer trends, changes in supply chain [sourcing], geopolitical events, and the like.”
The Port Authority of New York & New Jersey was the second-busiest containerport year-to-date, handling nearly 1.6 million TEUs since the first of the year. The seaport moved 676,311 TEUs in May 2023, 5.1% more cargo than in pre-pandemic May 2019. “Things have been soft and below where we would certainly like them to be,” says Beth Rooney, director of the port department for the New York/New Jersey Port Authority. “That being said, we are trending higher than [in the same period in] 2019. We’re in pretty good shape.”
TWO SCENARIOS
Lars Jensen, CEO and partner with consulting firm Vespucci Maritime, sees two possible scenarios for the maritime industry going forward. “One is where the market gets worse—which from a headline perspective, is the easiest argument to make. Why? We still have a lot of extra capacity in the market, rates have been trending downward, and blank [canceled] sailings have been increasing,” he notes. On top of that is the persistent issue of “a continued overhang of inventory that is not being cleared fast enough and that is depressing volumes.”
Yet it’s not a “slam dunk” that a continued downturn is in the market’s future, opines Jensen, who also says “there is actually a legitimate argument that the market is going in the exact opposite direction. History tells us that markets driven by inventory correction, once that is done, typically rebound a lot faster than anyone expects.”
“If the doomsayers of a recession are wrong, then you could see the market snap back very quickly, and we could see a strong peak season,” he continues. “We will eventually hit bottom [if we haven’t already], and once that happens, we will see a rebound, one that could happen quickly to drive demand.”
Beth Rooney makes a similar point about an inventory overhang. “What we have been doing for the last six to nine months is living off the bloated inventory that [has] accumulated. There was so much panic buying during the pandemic on the part of shippers who were afraid of running out of inventory. They bought early and often. We have been living off that excess inventory.”
That reality was reinforced in a meeting Rooney and her team had in June with the largest sporting goods retailer in the U.S. “They were very open that they were living off [bloated] inventory; they bought too much, too soon,” she says.
A common refrain among retailers she’s talked with is that they were faced with the conundrum of liquidating goods that missed their seasonal window, went out of style, or became obsolete. Until they did so, “there was no room at the inn …. Warehouses were full, and they couldn’t bring in the summer outdoor furniture because they were still liquidating snow blowers,” she notes.
LESS DWELL, MORE DIVERSION
One issue that thankfully has no longer been a problem for Rooney as well as her fellow port operators is excessive dwell, or delay in containers moving out of the port. Last year, the New York/New Jersey Port Authority, in cooperation with drayage firms, liner operators, and terminal operators, instituted an empty-container evacuation program to address extended dwell issues.
“It’s gone very well; we didn’t have to charge any of the assessments if carriers did not follow through,” she says. “That helped restore fluidity and got the truckers the opportunity to return the empties that were in the yard, holding up chassis, and preventing the next import from coming in.”
The improvement was dramatic. “In dwell alone, at our worst we were upwards of 21 days average dwell time,” Rooney notes. “Last week, our average dwell was 3.36 days.”
There also continues to be some diversion of cargo from West Coast destinations to Gulf and East Coast ports. Some of that is an outgrowth of pandemic-induced congestion that initially created problems at West Coast ports, exacerbated over the past nine months by shipper angst over labor negotiations. “We continue to gain market share on West Coast ports,” says Rooney. Shippers are telling her that until the West Coast labor contract is fully ratified, “they are not racing to go back.”
Nevertheless, Long Beach’s Cordero points out that while the American shipper has choices for Asia-U.S. cargo movement, “the San Pedro Bay complex remains the No. 1 gateway” for U.S. shippers, and he expects them to eventually make routing changes that will return more cargo to the West Coast. “It will remain competitive,” he says, citing the port’s “billions in capital improvement programs” as a major incentive for shippers and vessel operators, particularly Long Beach’s investments in on-dock rail, efficiency, and cargo velocity.
RECORD PROFITS NO MORE
Ship operators are coming off two years of record profits. As they head into the remainder of 2023 and on into 2024, they are instituting cost-saving moves like slow steaming, resulting in longer transit times and blanked sailings, while idling some capacity and sending other older vessels to the scrapyard. At the same time, they’re preparing for a coming wave of new, larger vessels that will be brought online over the next few years, which will portend still more changes and challenges for operators and shippers alike.
“New vessels are already being delivered,” notes Vespucci Maritime’s Jensen. With deliveries representing 10% of market capacity projected to come online this year and next year, “it’s easy to make the case that we could again be in an overcapacity situation.”
Jensen says ship operators are “slowing everything down,” particularly in the Asia-Europe and European Community trade lanes. “That will absorb quite a bit of the new capacity; they are putting extra vessels on every string.” Another factor impacting capacity is ship operators parking vessels, which he estimates is currently about 3% of the worldwide fleet.
Jensen also expects to see a ramp-up in the scrapping of older vessels, with this year and next year seeing some 70,000 TEUs of capacity exiting the market. High charter rates last year, which kept many older vessels in service, have declined precipitously, accelerating their exit. And last but not least are coming environmental regulations, which will force out many older, noncompliant vessels and will require vessel operators to invest in new ships and push their fleets to run cleaner than ever before.
Stuart Sandlin, president of the North America region for global containership operator Hapag-Lloyd, agrees with others that “on the demand side, import markets have been weaker … [largely] due to a global economic slowdown and unusually high inventories.” However, he adds, “we have recently seen demand start to rise slightly in some selected trades. I would anticipate that demand is likely to remain subdued until the destocking cycle is completed.”
From a supply perspective, Sandlin notes that “a strong inflow of new capacity will be partially offset by an increase in scrapping activities and slow steaming. This will be exacerbated by the International Maritime Organization’s CII regulation, which impacts less fuel-efficient ships. (CII stands for “Carbon Intensity Indicator,” which is a measure of how efficiently a ship transports goods or passengers.) Sandlin goes on to say, “I anticipate that supply will likely outpace demand in 2023 and 2024, making active cost management inevitable.” A bright spot for liner operators: growth in the Asia-to-Mexico trade lane, supported by a rise in nearshoring of manufacturing and production capacity among many industries.
It is a similar story at Maersk, the world’s largest containership fleet operator. The company continues to anticipate that the inventory correction will have run its course by mid-year, “leading to a more balanced demand environment” for the second half of the year, as the carrier noted in its Q1 earnings statement. That projection is beginning to come into focus as Maersk “has begun to see an uptick in cargo flows common to peak season shipping, as the flow of back-to-school, fall fashion, and end-of-the-year holiday goods begins to come into North America,” noted a Maersk spokesperson.
One area Maersk (and other ship operators) is monitoring closely is the draft adjustments announced by the Panama Canal Authority. As of mid-June, “the authority communicated that a maximum draft of 44 feet is in effect for the Neopanamax locks,” explained the Maersk spokesperson. (Neopanamax, or “new” Panamax, is a term that relates to the size of the containerships or other vessels that are able to transit the now-widened Panama Canal.) That reduction is a drop of six feet since restrictions were first announced in March. Low water levels prevent some larger ships from transiting the canal and force ship operators to divert cargo over other routes, such as the Suez Canal.
And while local weather conditions continue to affect the water levels the Panama Canal requires for operation, “in compliance with [current] draft restrictions, we are optimizing our network planning and vessel loading accordingly,” said the spokesperson. Maersk continues to offer multiple sailings per week through Panama.
THE SHIPPER’S PERSPECTIVE
Ocean freight “has not bottomed out. It’s a longer cycle going down and not as fast coming back up,” says Andy Dyer, president, transportation management for AFS Logistics. “There just isn’t enough freight out there. Everyone is hoping for a peak season, but no one is holding their breath.”
U.S.-based AFS operates as a freight forwarder and broker for ocean freight, dealing directly with ship lines on behalf of AFS customers to arrange and route freight. Dyer sees a market “fresh off the crack of the bullwhip effect from Covid,” a seminal market event that’s been longer in duration than anyone expected and whose impact “is still echoing in people’s ears.”
Does he expect a second-half pickup in ocean freight volumes? Maybe. “What really comes into play is material consumption,” he’s observed. “One saving grace is that the consumer has continued to buy, even as we have seen a lot of inflation. There was a big bubble in demand for goods, retailers over-inventoried, [and then] demand from consumers dropped as they switched spending to services. Just look at what’s happened with airline, hotel, and rental car prices.”
With a stable yet relatively tepid economy, Dyer does not expect demand for ocean freight to explode anytime soon. “We’ve been working off a mountain of inventory. And it’s not done yet,” he notes. One lesson he believes shippers have learned: the importance of de-risking and diversifying supply chains and sourcing nodes.
“People are looking at the nodes and flows in their supply chains and realizing they have to change, reduce risk, and improve reliability—as well as manage cost,” he says. “It’s not just the number of suppliers; it’s where they are [and] having reliable secondary sources that can jump in when a primary is compromised.
“Let’s face it, if you were relying on China, as many have for years, just moving to another part of Asia may not always be the best answer,” he notes, adding that people are thinking more broadly.
“Making those types of changes, and then seeing those manifest themselves in freight from new locations, doesn’t happen overnight. Untangling and replacing some of those global relationships can be a years-long process.”
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."
Keep ReadingShow less
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.