Top 10 Supply Chain Threats: Marc Palazzolo of Kearney on the threat of the freight capacity crunch
The supply chain is no stranger to freight capacity issues, but the pandemic has exacerbated an already difficult challenge. What can shippers do to ease the risks associated with the capacity crunch in 2022?
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Transcript
About this week's guest
Marc Palazzolo is manager of strategic operations at consulting firm Kearney. He has led last-mile delivery strategy for Amazon Prime Now, Fresh, and Whole Foods NYC and has helped many companies revamp their supply chain operations. Palazzolo has more than five years of industry experience in the areas of last-mile delivery strategy, e-commerce fulfillment, supply chain strategy and transformation, distribution excellence, distribution-center four-walls improvement, and logistics sourcing. He is the co-author of CSCMP State of Logistics Report, Parcel / Last Mile.
David Maloney, Editorial Director, CSCMP’s Supply Chain Quarterly00:02
The Covid-19 pandemic showed us just how vulnerable supply chains are. Today we face many threats: shipping delays; a lack of workers; failing infrastructure; transportation rates that are out of control; cybersecurity threats; and of course, a worldwide pandemic that is still very much with us. But with each of these threats comes opportunities. Welcome to this limited podcast series from CSCMP’s Supply Chain Quarterly, the Top 10 Supply Chain Threats.
This podcast is sponsored by AFS Logistics, offering trusted logistics services for parcel, LTL, freight audit and payment, and transportation management. AFS combines a data-driven approach with time-tested skills to help you navigate, find, and optimize the freight capacity you need when you need it. For more information, visit AFS.net.
Today, we focus on the threat of a freight capacity crunch. Here's your moderator for this segment, Supply Chain Quarterly's managing editor, Diane Rand.
Joining us today is Marc Palazzolo. He currently serves as a manager of strategic operations at consulting firm Kearney, and before joining Kearney he worked at Amazon for several years. Thank you for being here today, Marc, to discuss the freight capacity crunch affecting supply chains. Can you summarize some of the main freight capacity issues that we're currently facing?
Marc Palazzolo, Manager, Strategic Operations, Kearney 01:36
Yeah, thank you, Diane and pleasure to be here. So, in terms of freight capacity issues that we're currently facing, there's multiple factors driving, really the crisis that we're all facing and have been facing for about the past 18 months. Based on conversations that I'm having with clients, there's really two key aspects, which I think are most critical. Number one is the rapid acceleration to e-commerce. So, with the pandemic driving more consumers online, this has accelerated e-commerce about five years within a, you know, less than two-year period. This shift is really resulted in a few supply chain challenges that both shippers and carriers weren't in a position to address quickly. For example, with the shift to e-commerce, that results in smaller shipment volume with more replenishment cycles, also results in increased delivery speed expectations, and overall greater shipment volume across all modes. With that drastic rise in e-commerce we've seen, and continue to forecast, that's really a driver of this capacity challenge in the market. Number two is the driver shortage. So, as shipment volumes rise, this has only exacerbated the existing driver shortage. With a generally aging workforce, among other factors, the U.S. driver shortage is expected to be upwards of 100,000 over the next two years, which is further going to impact the capacity issues shippers are facing, unless strategic interventions are made. Those are really the two key aspects or factors that I'm hearing from clients.
And so what are some of the repercussions of those issues if we don't, as a[n] industry, tackle them and get some relief here soon?
Marc Palazzolo, Manager, Strategic Operations, Kearney 03:22
The repercussions if not holistically and strategically addressed, are significant. For my clients, the top-of-mind repercussions are really threefold. Number one is service. The key question executives are asking themselves is, How do I meet current customer expectations as well as deliver on increased demands brought on by this explosion e-commerce? Number two is cost. As we all know, operating costs across all modes have skyrocketed. For example, freight dry-van rates have increased 31% year over year, during an already inflationary period. Parcel and ocean are being impacted on [an] even greater scale. So, executives are asking themselves, How can I combat these significant cost headwinds and not have my EBITDA impacted? And the third, which I think is really important, is shippers are concerned about lost sales due to not having inventory in the right place at the right time, due to this tightened freight capacity. And so with with growth being ever important in today's marketplace, this is really top of mind for clients and executives.
The big question on everyone's mind these days is, when can we expect these freight capacity problems to ease?
Marc Palazzolo, Manager, Strategic Operations, Kearney 04:33
Yeah, in terms of timeline for relief, I believe we're looking at end of 2022, if not into Q1 or Q2 of 2023 for the market to normalize. Unfortunately, many shippers have typically taken a more short-term approach to supply chain resiliency, and therefore organizations are currently unable to adapt and course-correct as fast as they desire. That said, there there are a variety of strategies which supply chain executives and organizations can pursue to combat these current challenges, but I think that journey is going to take us, you know, into next year if not into middle of 2023.
It sounds about right. High capacity in one mode puts more pressure on capacity in another mode, or other modes. Do you see any potential domino effects on the horizon that shippers should be watching?
Marc Palazzolo, Manager, Strategic Operations, Kearney 05:26
There isn't one particular domino effect that I foresee or think that shippers should really be watching for, as the, you know, the problem space is highly interconnected. Rather, I'm of the perspective that shippers should be taking a holistic approach to enhancing resiliency and flexibility of their supply chain to jointly optimize for capacity costs and service. As you said, as you start to lean on one mode versus another, you start to shift that constraint, and so taking a step back and approaching holistically is a strategy to ultimately enhance your resiliency and not move forward with that domino effect.
So beyond taking a holistic approach, is there anything else shippers can do to alleviate some of this strain, or do you think they just have to write it out to a certain extent?
Marc Palazzolo, Manager, Strategic Operations, Kearney 06:16
There are certainly short term levers that shippers can pull to alleviate the current pain that they're feeling. That said, I think a longer-term strategy across three prongs is really what is needed here, and a more surgical approach is needed here to enhance supply chain resiliency and ultimately mitigate future supply chain disruption. Number one is adopting an end-to-end supply chain approach and addressing structural changes. So, one of the first structural changes is thinking about how to strategically diversify your carrier supply base across all modes to minimize disruption. For example, even if a key supplier or key carriers not meeting SLAs duty reduce capacity, or if they're going to increase costs due to disruption in their supply chain, you're able to across modes or even within lanes, shift to other carriers. That's one structural change that clients have been deploying to start mitigating some of the disruption and challenges. A second element here is evaluating the ability to localize components of your supply chain to limit those disruptions on a national or global scale. This localization play also enables a shift from OTR parcel volume to other last-mile carriers such as Shipt, DoorDash, Roadie, [Walmart, local?] etc.—some of those other gig economy players that have more flexibility due to their operating model. So, again, adopting this end-to-end approach and addressing these structural changes is one component that we think is key. The second component is doubling down on investments in advanced technologies, with a particular focus on exception management or [sensitive pivot] technologies, which have predictive analytics. This allows supply chain organizations to be able to proactively identify issues and take action prior to avoid a disruption. Now, there has to be a strategic evaluation of that capex and opex trade off, but that is one—that is an area that leaders are taking to make their supply chains more future proof. The last and third prong of the strategy that we're recommending for clients is optimizing your operating model. From my perspective, as I said previously, many companies are responding to turbulence in the logistics market in a very tactical and reactive way, but to be able to make their supply chain more resilient, having that long-term approach and thinking about their operating model more strategically, is really key. More specifically, these longer-term strategies will focus on enabling real-time shipment visibility, driving flexibility to pivot quickly as exceptions and those choke points arise, and implementing analytics that continually monitor your logistics network to anticipate potential disruptions and assess performance. Those are really the three key things that I think, from a longer-term perspective, shippers can deploy to be able to ride out this turbulence.
Wonderful advice. Thank you so much for being with us today to talk to us about the freight capacity crunch that's affecting our supply chains, and it'll be interesting to see what the next year or so will bring, and how our industry will change and shift and grow, and some of the innovations that will come out of it. Just—it'll be interesting to see how that, how it all shakes out. So, thank you, Marc, for your time today. We really do appreciate you coming on and talking to us.
Marc Palazzolo, Manager, Strategic Operations, Kearney 09:59
Absolutely, Diane, it was a pleasure and really enjoyed the conversation. Thank you.
David Maloney, Editorial Director, CSCMP’s Supply Chain Quarterly10:07
Thank you for joining us for this podcast from CSCMP’s Supply Chain Quarterly, the Top 10 Supply Chain Threats. We encourage you to subscribe wherever you get your podcasts.
First, 54% of retailers are looking for ways to increase their financial recovery from returns. That’s because the cost to return a purchase averages 27% of the purchase price, which erases as much as 50% of the sales margin. But consumers have their own interests in mind: 76% of shoppers admit they’ve embellished or exaggerated the return reason to avoid a fee, a 39% increase from 2023 to 204.
Second, return experiences matter to consumers. A whopping 80% of shoppers stopped shopping at a retailer because of changes to the return policy—a 34% increase YoY.
Third, returns fraud and abuse is top-of-mind-for retailers, with wardrobing rising 38% in 2024. In fact, over two thirds (69%) of shoppers admit to wardrobing, which is the practice of buying an item for a specific reason or event and returning it after use. Shoppers also practice bracketing, or purchasing an item in a variety of colors or sizes and then returning all the unwanted options.
Fourth, returns come with a steep cost in terms of sustainability, with returns amounting to 8.4 billion pounds of landfill waste in 2023 alone.
“As returns have become an integral part of the shopper experience, retailers must balance meeting sky-high expectations with rising costs, environmental impact, and fraudulent behaviors,” Amena Ali, CEO of Optoro, said in the firm’s “2024 Returns Unwrapped” report. “By understanding shoppers’ behaviors and preferences around returns, retailers can create returns experiences that embrace their needs while driving deeper loyalty and protecting their bottom line.”
Facing an evolving supply chain landscape in 2025, companies are being forced to rethink their distribution strategies to cope with challenges like rising cost pressures, persistent labor shortages, and the complexities of managing SKU proliferation.
1. Optimize labor productivity and costs. Forward-thinking businesses are leveraging technology to get more done with fewer resources through approaches like slotting optimization, automation and robotics, and inventory visibility.
2. Maximize capacity with smart solutions. With e-commerce volumes rising, facilities need to handle more SKUs and orders without expanding their physical footprint. That can be achieved through high-density storage and dynamic throughput.
3. Streamline returns management. Returns are a growing challenge, thanks to the continued growth of e-commerce and the consumer practice of bracketing. Businesses can handle that with smarter reverse logistics processes like automated returns processing and reverse logistics visibility.
4. Accelerate order fulfillment with robotics. Robotic solutions are transforming the way orders are fulfilled, helping businesses meet customer expectations faster and more accurately than ever before by using autonomous mobile robots (AMRs and robotic picking.
5. Enhance end-of-line packaging. The final step in the supply chain is often the most visible to customers. So optimizing packaging processes can reduce costs, improve efficiency, and support sustainability goals through automated packaging systems and sustainability initiatives.
That clash has come as retailers have been hustling to adjust to pandemic swings like a renewed focus on e-commerce, then swiftly reimagining store experiences as foot traffic returned. But even as the dust settles from those changes, retailers are now facing renewed questions about how best to define their omnichannel strategy in a world where customers have increasing power and information.
The answer may come from a five-part strategy using integrated components to fortify omnichannel retail, EY said. The approach can unlock value and customer trust through great experiences, but only when implemented cohesively, not individually, EY warns.
The steps include:
1. Functional integration: Is your operating model and data infrastructure siloed between e-commerce and physical stores, or have you developed a cohesive unit centered around delivering seamless customer experience?
2. Customer insights: With consumer centricity at the heart of operations, are you analyzing all touch points to build a holistic view of preferences, behaviors, and buying patterns?
3. Next-generation inventory: Given the right customer insights, how are you utilizing advanced analytics to ensure inventory is optimized to meet demand precisely where and when it’s needed?
4. Distribution partnerships: Having ensured your customers find what they want where they want it, how are your distribution strategies adapting to deliver these choices to them swiftly and efficiently?
5. Real estate strategy: How is your real estate strategy interconnected with insights, inventory and distribution to enhance experience and maximize your footprint?
When approached cohesively, these efforts all build toward one overarching differentiator for retailers: a better customer experience that reaches from brand engagement and order placement through delivery and return, the EY study said. Amid continued volatility and an economy driven by complex customer demands, the retailers best set up to win are those that are striving to gain real-time visibility into stock levels, offer flexible fulfillment options and modernize merchandising through personalized and dynamic customer experiences.
Geopolitical rivalries, alliances, and aspirations are rewiring the global economy—and the imposition of new tariffs on foreign imports by the U.S. will accelerate that process, according to an analysis by Boston Consulting Group (BCG).
Without a broad increase in tariffs, world trade in goods will keep growing at an average of 2.9% annually for the next eight years, the firm forecasts in its report, “Great Powers, Geopolitics, and the Future of Trade.” But the routes goods travel will change markedly as North America reduces its dependence on China and China builds up its links with the Global South, which is cementing its power in the global trade map.
“Global trade is set to top $29 trillion by 2033, but the routes these goods will travel is changing at a remarkable pace,” Aparna Bharadwaj, managing director and partner at BCG, said in a release. “Trade lanes were already shifting from historical patterns and looming US tariffs will accelerate this. Navigating these new dynamics will be critical for any global business.”
To understand those changes, BCG modeled the direct impact of the 60/25/20 scenario (60% tariff on Chinese goods, a 25% on goods from Canada and Mexico, and a 20% on imports from all other countries). The results show that the tariffs would add $640 billion to the cost of importing goods from the top ten U.S. import nations, based on 2023 levels, unless alternative sources or suppliers are found.
In terms of product categories imported by the U.S., the greatest impact would be on imported auto parts and automotive vehicles, which would primarily affect trade with Mexico, the EU, and Japan. Consumer electronics, electrical machinery, and fashion goods would be most affected by higher tariffs on Chinese goods. Specifically, the report forecasts that a 60% tariff rate would add $61 billion to cost of importing consumer electronics products from China into the U.S.
That strategy is described by RILA President Brian Dodge in a document titled “2025 Retail Public Policy Agenda,” which begins by describing leading retailers as “dynamic and multifaceted businesses that begin on Main Street and stretch across the world to bring high value and affordable consumer goods to American families.”
RILA says its policy priorities support that membership in four ways:
Investing in people. Retail is for everyone; the place for a first job, 2nd chance, third act, or a side hustle – the retail workforce represents the American workforce.
Ensuring a safe, sustainable future. RILA is working with lawmakers to help shape policies that protect our customers and meet expectations regarding environmental concerns.
Leading in the community. Retail is more than a store; we are an integral part of the fabric of our communities.
“As Congress and the Trump administration move forward to adopt policies that reduce regulatory burdens, create economic growth, and bring value to American families, understanding how such policies will impact retailers and the communities we serve is imperative,” Dodge said. “RILA and its member companies look forward to collaborating with policymakers to provide industry-specific insights and data to help shape any policies under consideration.”