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.
Supply chains are poised for accelerated adoption of mobile robots and drones as those technologies mature and companies focus on implementing artificial intelligence (AI) and automation across their logistics operations.
That’s according to data from Gartner’s Hype Cycle for Mobile Robots and Drones, released this week. The report shows that several mobile robotics technologies will mature over the next two to five years, and also identifies breakthrough and rising technologies set to have an impact further out.
Gartner’s Hype Cycle is a graphical depiction of a common pattern that arises with each new technology or innovation through five phases of maturity and adoption. Chief supply chain officers can use the research to find robotic solutions that meet their needs, according to Gartner.
Gartner, Inc.
The mobile robotic technologies set to mature over the next two to five years are: collaborative in-aisle picking robots, light-cargo delivery robots, autonomous mobile robots (AMRs) for transport, mobile robotic goods-to-person systems, and robotic cube storage systems.
“As organizations look to further improve logistic operations, support automation and augment humans in various jobs, supply chain leaders have turned to mobile robots to support their strategy,” Dwight Klappich, VP analyst and Gartner fellow with the Gartner Supply Chain practice, said in a statement announcing the findings. “Mobile robots are continuing to evolve, becoming more powerful and practical, thus paving the way for continued technology innovation.”
Technologies that are on the rise include autonomous data collection and inspection technologies, which are expected to deliver benefits over the next five to 10 years. These include solutions like indoor-flying drones, which utilize AI-enabled vision or RFID to help with time-consuming inventory management, inspection, and surveillance tasks. The technology can also alleviate safety concerns that arise in warehouses, such as workers counting inventory in hard-to-reach places.
“Automating labor-intensive tasks can provide notable benefits,” Klappich said. “With AI capabilities increasingly embedded in mobile robots and drones, the potential to function unaided and adapt to environments will make it possible to support a growing number of use cases.”
Humanoid robots—which resemble the human body in shape—are among the technologies in the breakthrough stage, meaning that they are expected to have a transformational effect on supply chains, but their mainstream adoption could take 10 years or more.
“For supply chains with high-volume and predictable processes, humanoid robots have the potential to enhance or supplement the supply chain workforce,” Klappich also said. “However, while the pace of innovation is encouraging, the industry is years away from general-purpose humanoid robots being used in more complex retail and industrial environments.”
Even as the e-commerce sector overall continues expanding toward a forecasted 41% of all retail sales by 2027, many small to medium e-commerce companies are struggling to find the investment funding they need to increase sales, according to a sector survey from online capital platform Stenn.
Global geopolitical instability and increasing inflation are causing e-commerce firms to face a liquidity crisis, which means companies may not be able to access the funds they need to grow, Stenn’s survey of 500 senior e-commerce leaders found. The research was conducted by Opinion Matters between August 29 and September 5.
Survey findings include:
61.8% of leaders who sought growth capital did so to invest in advanced technologies, such as AI and machine learning, to improve their businesses.
When asked which resources they wished they had more access to, 63.8% of respondents pointed to growth capital.
Women indicated a stronger need for business operations training (51.2%) and financial planning resources (48.8%) compared to men (30.8% and 15.4%).
40% of business owners are seeking external financial advice and mentorship at least once a week to help with business decisions.
Almost half (49.6%) of respondents are proactively forecasting their business activity 6-18 months ahead.
“As e-commerce continues to grow rapidly, driven by increasing online consumer demand and technological innovation, it’s important to remember that capital constraints and access to growth financing remain persistent hurdles for many e-commerce business leaders especially at small and medium-sized businesses,” Noel Hillman, Chief Commercial Officer at Stenn, said in a release. “In this competitive landscape, ensuring liquidity and optimizing supply chain processes are critical to sustaining growth and scaling operations.”
With six keynote and more than 100 educational sessions, CSCMP EDGE 2024 offered a wealth of content. Here are highlights from just some of the presentations.
A great American story
Author and entrepreneur Fawn Weaver closed out the first day of the conference by telling the little-known story of Nathan “Nearest” Green, who was born into slavery, freed after the Civil War, and went on to become the first master distiller for the Jack Daniel’s Whiskey brand. Through extensive research and interviews with descendants of the Daniel and Green families, Weaver discovered what she describes as a positive American story.
She told the story in her best-selling book, Love & Whiskey: The Remarkable True Story of Jack Daniel, His Master Distiller Nearest Green, and the Improbable Rise of Uncle Nearest. That story also inspired her to create Uncle Nearest Premium Whiskey.
Weaver discussed the barriers she encountered in bringing the brand to life, her vision for where it’s headed, and her take on the supply chain—which she views as both a necessary cost of doing business and an opportunity.
“[It’s] an opportunity if you can move quickly,” she said, pointing to a recent project in which the company was able to fast-track a new Uncle Nearest product thanks to close collaboration with its supply chain partners.
A two-pronged business transformation
We may be living in a world full of technology, but strategy and focus remain the top priorities when it comes to managing a business and its supply chains. So says Roberto Isaias, executive vice president and chief supply chain officer for toy manufacturing and entertainment company Mattel.
Isaias emphasized the point during his keynote on day two of EDGE 2024. He described how Mattel transformed itself amid surging demand for Barbie-branded items following the success of the Barbie movie.
That transformation, according to Isaias, came on two fronts: commercially and logistically. Today, Mattel is steadily moving beyond the toy aisle with two films and 13 TV series in production as well as 14 films and 35 shows in development. And as for those supply chain gains? The company has saved millions, increased productivity, and improved profit margins—even amid cost increases and inflation.
A framework for chasing excellence
Most of the time when CEOs present at an industry conference, they like to talk about their companies’ success stories. Not J.B. Hunt’s Shelley Simpson. Speaking at EDGE, the trucking company’s president and CEO led with a story about a time that the company lost a major customer.
According to Simpson, the company had a customer of their dedicated contract business in 2001 that was consistently making late shipments with no lead time. “We were working like crazy to try to satisfy them, and lost their business,” Simpson said.
When the team at J.B. Hunt later met with the customer’s chief supply chain officer and related all they had been doing, the customer responded, “You never shared everything you were doing for us.”
Out of that experience, came J.B. Hunt’s Customer Value Delivery framework. The framework consists of five steps: 1) understand customer needs, 2) deliver expectations, 3) measure results, 4) communicate performance, and 5) anticipate new value.
Next year’s CSCMP EDGE conference on October 5–8 in National Harbor, Md., promises to have a similarly deep lineup of keynote presentations. Register early at www.cscmpedge.org.
2024 was expected to be a bounce-back year for the logistics industry. We had the pandemic in the rearview mirror, and the economy was proving to be more resilient than expected, defying those prognosticators who believed a recession was imminent.
While most of the economy managed to stabilize in 2024, the logistics industry continued to see disruption and changes in international trade. World events conspired to drive much of the narrative surrounding the flow of goods worldwide. Additionally, a diminished reliance on China as a source for goods reduced some of the international trade flow from that manufacturing hub. Some of this trade diverted to other Asian nations, while nearshoring efforts brought some production back to North America, particularly Mexico.
Meanwhile trucking in the United States continued its 2-year recession, highlighted by weaker demand and excess capacity. Both contributed to a slow year, especially for truckload carriers that comprise about 90% of over-the-road shipments.
Labor issues were also front and center in 2024, as ports and rail companies dealt with threats of strikes, which resulted in new contracts and increased costs. Labor—and often a lack of it—continues to be an ongoing concern in the logistics industry.
In this annual issue, we bring a year-end perspective to these topics and more. Our issue is designed to complement CSCMP’s 35th Annual State of Logistics Report, which was released in June, and includes updates that were presented at the CSCMP EDGE conference held in October. In addition to this overview of the market, we have engaged top industry experts to dig into the status of key logistics sectors.
Hopefully as we move into 2025, logistics markets will build on an improving economy and strong consumer demand, while stabilizing those parts of the industry that could use some adrenaline, such as trucking. By this time next year, we hope to see a full recovery as the market fulfills its promise to deliver the needs of our very connected world.
If you feel like your supply chain has been continuously buffeted by external forces over the last few years and that you are constantly having to adjust your operations to tact through the winds of change, you are not alone.
The Council of Supply Chain Management Professionals’ (CSCMP’s) “35th Annual State of Logistics Report” and the subsequent follow-up presentation at the CSCMP EDGE Annual Conference depict a logistics industry facing intense external stresses, such as geopolitical conflict, severe weather events and climate change, labor action, and inflation. The past 18 months have seen all these factors have an impact on demand for transportation and logistics services as well as capacity, freight rates, and overall costs.
The “State of Logistics Report” is an annual study compiled and authored by a team of analysts from Kearney for CSCMP and supported and sponsored by logistics service provider Penske Logistics. The purpose of the report is to provide a snapshot of the logistics industry by assessing macroeconomic conditions and providing a detailed look at its major subsectors.
One of the key metrics the report has tracked every year since its inception in 1988 is U.S. business logistics costs (USBLC). This year’s report found that U.S. business logistics costs went down in 2023 for the first time since the start of the pandemic. As Figure 1 shows, U.S. business logistics costs for 2023 dropped 11.2% year-over-year to $2.4 trillion, or 8.7% of last year’s $27.4 trillion gross domestic product (GDP).
“This was not unexpected,” said Josh Brogan, Kearney partner and lead author of the report, during a press conference in June announcing the results. “After the initial impacts of COVID were felt in 2020, we saw a steady rise of logistics costs, even in terms of total GDP. What we are seeing now is a reversion more toward the mean.”
This breakdown of U.S. Business Logistics Costs for 2023 shows an across-the-board decline in all transportation costs.
CSCMP's 35th Annual "State of Logistics Report"
As a result, Figure 1 shows an across-the-board decline in transportation costs (except for some administrative costs) for the 2023 calendar year. “What such a chart cannot fully capture about this period is the intensification of certain external stressors on the global economy and its logistical networks,” says the report. “These include a growing geopolitical instability that further complicates investment and policy decisions for business leaders and government officials.”Both the report and the follow-up session at the CSCMP EDGE Conference in October provided a vivid picture of the global instability that logistics providers and shippers are facing. These conditions include (but are not limited to):
An intensification of military conflict, with the Red Sea Crisis being particularly top of mind for companies shipping from Asia to Europe or to the eastern part of North America;
Continued fragmentation of global trade, as evidenced by the deepening rift between China and the United States;
Climate change and severe weather events, such as the drought in Panama, which lowered water levels in the Panama Canal, and the two massive hurricanes that ripped through the Southeastern United States;
Labor disputes, such as the three-day port strike which stopped operations at ports along the East and Gulf Coasts of the United States in October; and
Persistent inflation (despite some recent improvement in the United States) and muted global economic growth.
At the same time that the logistics market was dealing with these external factors, it was also facing sluggish freight demand and an ongoing excess of capacity. These twin dynamics have contributed to continued low cargo rates through 2024.
“For 2024, I foresee a generally flat USBLC as a percentage of GDP,” says Brogan. “We did see increases in air and ocean costs in preparation for the East Coast port strike but overall, road freight is down. I think this will balance out with the relatively low level of inflation seen in the general economy.”
Breakdown by mode
The following is a quick review of how the forces outlined above are affecting the primary logistics sectors, as described by the “State of Logistics Report” and the updated presentation given at the CSCMP EDGE Conference in early October.
Trucking: A downturn in consumer demand plus a lingering surplus in capacity led to a plunge in rates in 2023 compared to 2022. Throughout 2024, however, rates have remained relatively stable. Speaking in October, report author Brogan said he expects that trend to continue for the near future. On the capacity side, despite thousands of companies having departed the market since 2022, the number of departures has not been as high as would normally be expected during a down market. Brogan accounts this to investors expecting to see some turbulence in the marketplace and being willing to stick around longer than has traditionally been the case.
Parcel and last mile: Parcel volumes in 2023 were down by 0.5% compared to 2022. Simultaneously, there has been a move away from UPS and FedEx, both of which saw their year-over-year parcel volumes decline in 2023. Nontraditional competitors have taken larger portions of the parcel volume, including Amazon, which passed UPS for the largest parcel carrier in the U.S. in 2023. Additionally, there has been an increasing use of regional providers, as large shippers continue to shift away from “single sourcing” their carrier base. Parcel volumes have increased in 2024, mostly driven by e-commerce. Brogan expects regional providers to claim “the lion’s share” of this volume.
Rail: In 2023, Class I railroads experienced a challenging financial environment, characterized by a 4% increase in operating ratios, a 2% decline in revenue, and an 11% decrease in operating income compared to 2022. These financial troubles were primarily driven by intermodal volume decreases, service challenges, inflationary pressures, escalated fuel and labor expenses, and a surge in employee headcount. The outlook for 2024 is slightly more promising, according to Kearney. Intermodal, often regarded a primary growth driver, has seen increased volumes and market share. Class I railroads are also seeing some positive operational developments with train speeds increasing by 2.3% and terminal dwell times decreasing by 1.8%. Finally, opportunities are opening up for an expansion in cross-border rail traffic within North America.
Air: The air freight market saw a steep decline in costs year over year from 2022 to 2023. Rates in 2024 began flat before starting to pick up in the summer, and report authors expect to see demand increase by 4.5%. Part of the demand pickup is due to disruptions in key sea lanes, such as the Suez Canal, causing shippers to convert from ocean to air. Meanwhile, the capacity picture has been mixed with some lanes having a lot of capacity while others have none. Much of this dynamic is due to Chinese e-commerce retailers Temu and Shein, which depend heavily on airfreight to execute their business models. In order to serve this booming business, some airfreight providers have pulled capacity out of more niche markets, such as flights into Latin America or Africa, and are now using those planes to serve the Asia-to-U.S. or Asia-to-Europe lanes.
Water/ports: The recent “State of Logistics Report” indicated that waterborne freight experienced a very steep decline of 64.2% in expenditures in 2023 relative to 2022. This was mostly due to muted demand, overcapacity, and a normalization from the inflated ocean rates seen during the pandemic years. After the trough of 2023, the market has been seeing significant “micro-spikes” in rates on some lanes due to constraints caused by geopolitical issues, such as the Red Sea conflict and the U.S. East and Gulf Coast ports strike. Kearney foresees a continuation of these rate hikes for the next few months. However, over the long term, the market will have to deal with the overcapacity that was built up during the height of the pandemic, which will cause rates to soften. Ultimately, however, Brogan said he did not expect to see a return to 2023 rate levels.
Third-party logistics (3PLs): The third-party logistics (3PL) sector is facing some significant challenges in 2024. Low freight rates and excess capacity could force some 3PLs to consolidate, especially if they are smaller players and rely on venture capital funding. Meanwhile, Kearney reports that there is some redefining of traditional roles going on within the 3PL-shipper ecosystem. For example, some historically asset-light 3PLs are expanding into asset-heavy services, and some shippers are trying to monetize their own logistics capabilities by marketing them externally.
Freight forwarding: Major forwarders had a shaky final quarter of 2023, seeing a decline in financial performance. To regain form, Kearney asserts that forwarders will need to increase their focus on technology, value-added services, and tiered servicing. Overall, the forwarding sector is expected to grow at slow rate in coming years, with a projected annual growth rate of 5.5% for the period of 2023–2032.
Warehousing: According to Brogan an interesting phenomenon is occurring in the warehousing market with the average asking rents continuing to rise even though vacancy rates have also increased. There are several reasons for this mixed message, according to the “State of Logistics” report, including: longer contract durations, enhanced facility features, and steady demand growth. A record-breaking level of new construction and new facilities, however, have helped to stabilize rent prices and increase vacancy rates, according to the report authors.
Path forward
What is the way forward given these uncertain times? For many shippers and carriers, a fresh look at their networks and overall supply chains may be in order. Many companies are currently reassessing their distribution networks and operations to make sure that they are optimized. In these cost-sensitive times, that may involve consolidating facilities, eliminating redundant capacity, or rebalancing inventory.
It’s important to realize, however, that network optimization should not just focus on eliminating unnecessary costs. It should also ensure that the network has the right amount of capacity to response with agility and flexibility to any future disruptions. Companies must look at their supply chain networks as a whole and think about how they can be utilized to unlock strategic advantage.