After three years of pandemic-driven turmoil, the air freight market is finally normalizing. The lessons learned from that historic period will hopefully prepare us for what lies ahead.
Balika Sonthalia is a senior partner and leads global management in the Strategic Operations practice of Kearney, a global management consulting firm, specializing in procurement, supply chain, and logistics.
After battling tight capacity and unprecedentedly high rates for more than two years, the air freight market finally reached its tipping point in 2022 and started trending down. The relatively acute downturn was much welcomed by shippers, but it did force carriers and forwarders into a sudden reverse gear. As the market goes through its post-pandemic reset, it continues facing opportunities and challenges brought by macroeconomic, geopolitical, and environmental uncertainties.
The turning point
Throughout 2020 and 2021, the entire air freight market revolved around a single key word: capacity. The lack of capacity sent freight rates shooting up to historic levels, spurred by unprecedentedly high usage of charter planes and producing the most lucrative few years for the industry. From 2019 to 2021, global air cargo revenue increased by almost 100%, passing a historic high of $200 billion in 2021.
Reluctant to turn down shipping orders and constantly lose revenue opportunities, carriers started making capital investments in response to the boom, including buying or leasing new aircraft and conducting passenger-to-freighter conversions. In 2022, as travel restrictions were lifted in more regions, air travel rebounded, making belly capacity on passenger flights more available to shippers.
However, this increase in capacity was not met by a matching uptick in demand. In fact, the exact opposite. Air cargo volumes fell 8% in 2022 compared to the previous year. Consumer demand had stalled, and retailers realized their previous adrenaline rush to stock up had led to inventory surpluses.
This new supply-and-demand dynamic turned the tables. During 2022, Drewry’s East-West Air Freight Index dropped over 30% and continued trending down. It became clear that the market was normalizing.
What is gone, and what’s here to stay?
It has now been over a year since the market pivoted and started resetting. As we look back at the extraordinary couple of years through a rearview mirror with mixed feelings, what do we see?
Carriers’ rush to build up capacity certainly cooled down. Maersk Air Cargo has temporarily parked several leased cargo jets and reduced flight activity in response to declining demand. FedEx was reducing flight hours by 8% and parking more aircraft earlier this year because of continued low demand. On the shippers’ side, supply chain leaders are aiming at resetting pricing as well as their strained carrier relationships by conducting large-scale air freight sourcing. These competitive sourcing events resulted in significant value capture for shippers through not only big rate reductions but also removal of some pandemic-triggered unique phenomena, such as the need for charter planes, overcapacity surcharges, and other accessorial charges. Furthermore, shippers are leveraging these market events to reset their supplier portfolio. They are rewarding those carriers and forwarders that were true strategic partners during the challenging times by giving them expanded business.
During the pandemic, as they faced skyrocketing freight costs, many heavy users of air freight realized that they were mismanaging some of their shipments. For example, they were overusing certain service levels or not planning their shipments effectively. This mismanagement was exacerbated in the capacity-constrained market, causing organizations to “bleed” air freight spend. Reflecting upon lessons learned, many shippers have started making operational changes, such as reducing the frequency of intracompany shipments while consolidating loads, rationalizing service levels on high frequency lanes, and standardizing transit-time requirements. These sorts of improvements should continue even though market conditions have changed. What shippers seem to be still struggling with is integrating their demand planning with their operational functions to make their air freight demand more predictable, which would, in turn, help shorten lead times, reduce spot buys, and control overall costs.
A new era
The shocks of the pandemic might be a thing of the past, but some systemic macroeconomic changes are still happening, which will likely have transformational impact on the cargo air industry for years to come.
During the pandemic, despite the turbulent market environment, the aviation industry took on an unprecedented “challenge of our generation”: global warming. In October 2021, the International Air Transport Association (IATA), which represents some 300 airlines comprising 83% of global air traffic, approved “Fly Net Zero,” a resolution to achieve net-zero carbon emissions by 2050. This commitment aligns the industry goal with the Paris Agreement of preventing global warming from exceeding 1.5°C.
The IATA has created a plan to enable abating as much as 1.8 gigatons of carbon dioxide emissions in 2050. The industry will seek to make these reductions at the source through actions such as:
Adopting sustainable aviation fuels (SAF), which could account for 65% of those reductions,
Implementing zero-emission energy sources, such as electric and hydrogen power, which could account for 13% of the impact, and
Improving infrastructure and operational efficiency, which could contribute 3% of those reductions.
Any emissions that cannot be abated at the source will be eliminated through carbon capture, storage, and credible offsetting schemes.
Needless to say, the path to aviation net zero is challenging and costly. However, as IATA General Director Willie Walsh says, it is a necessary strategic step humanity must make “to ensure the freedom of future generations to sustainably explore, learn, trade, build markets, appreciate cultures, and connect with people the world over.”1 To achieve these milestones, airline companies must foster close collaboration across the entire aviation value chain and be supported by government policies and incentives that develop the required infrastructure and technology.
Another potential transformational force to the air cargo industry is the ongoing reshoring movement. Running through all of the numerous “x-shoring” terminology being developed (including reshoring, nearshoring, and friendshoring), there is one clear theme: The manufacturing landscape is shifting from global to increasingly regional as companies restructure their previously far-flung supply chains. If manufacturing and the corresponding supply chains become regionalized in the future, demand for long-distance international cargo will likely shrink. Meanwhile, major air freight corridors (for example, the transpacific) will likely re-arrange, with new hubs expanding in places such as Ho Chi Minh City, Mumbai, and Bangkok. Correspondingly, regional air cargo will likely pick up, as supply chains get decoupled into country clusters.
Regionalization will also drive further growth of road and rail transportation. Mexico started 2023 as the United States’ No. 1 trading partner, with total trade increasing 12% year over year to $64 billion. Correspondingly, trucks entering the U.S. at Laredo increased over 9% year over year in January. Reshoring and nearshoring should also boost demand for regional, short-distance ocean shipping.
After nearly 50 years of offshoring, the world is once again standing at a crossroads of its industrial manufacturing history. The exact impact of reshoring is far from clear, but it is certain that the overall supply chain and corresponding international freight landscape will be reshaped over the course of this new era.
Logistics real estate developer Prologis today named a new chief executive, saying the company’s current president, Dan Letter, will succeed CEO and co-founder Hamid Moghadam when he steps down in about a year.
After retiring on January 1, 2026, Moghadam will continue as San Francisco-based Prologis’ executive chairman, providing strategic guidance. According to the company, Moghadam co-founded Prologis’ predecessor, AMB Property Corporation, in 1983. Under his leadership, the company grew from a startup to a global leader, with a successful IPO in 1997 and its merger with ProLogis in 2011.
Letter has been with Prologis since 2004, and before being president served as global head of capital deployment, where he had responsibility for the company’s Investment Committee, deployment pipeline management, and multi-market portfolio acquisitions and dispositions.
Irving F. “Bud” Lyons, lead independent director for Prologis’ Board of Directors, said: “We are deeply grateful for Hamid’s transformative leadership. Hamid’s 40-plus-year tenure—starting as an entrepreneurial co-founder and evolving into the CEO of a major public company—is a rare achievement in today’s corporate world. We are confident that Dan is the right leader to guide Prologis in its next chapter, and this transition underscores the strength and continuity of our leadership team.”
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%."