U.S. logistics costs: Are we measuring the right things?
Inventory carrying costs represent a big chunk of the U.S. logistics costs measured by the annual "State of Logistics Report." Some would argue that carrying costs should be excluded.
When the first "State of Logistics Report" was released back in 1989, its author, the late Robert V. Delaney, established logistics expenditures as a percentage of the overall U.S. economy as the measure of logistics efficiency. He also set 10 percent as the benchmark for logistics success. A ratio below 10 percent of the U.S. gross domestic product (GDP), he said, indicated that logistics managers were doing an effective job of controlling costs and efficiently moving and storing goods. (Today the annual "State of Logistics Report" is authored by economist Rosalyn Wilson. It is sponsored by the Council of Supply Chain Management Professionals and presented by Penske Logistics.)
Delaney put forward that benchmark just a few years after the U.S. government deregulated transportation. His argument was that if deregulation unleashed market forces in the transportation sector, then transportation practices would become more efficient, transportation costs would be reduced, and the ratio of logistics costs to GDP would therefore decline. His prediction was correct: In 1981, before the industry felt the impact of trucking deregulation, logistics as a percentage of GDP stood at 16.2 percent. By 1995, that ratio had dropped to 10.4 percent.
For the next 10 years, the logistics-to-GDP ratio mostly stayed well under 10 percent. In 2005 it saw a substantial jump upward, and by the time the Great Recession hit in late 2007, it had reached 9.9 percent. But in 2009, during the nadir of the Great Recession, the ratio plummeted to 7.9 percent—the lowest level in the history of the report. That drop, by the way, was largely due to a decline in production rather than from any improvements in efficiency. Since then, it's hovered above 8 percent, and for the past two years (2011 and 2012) it's held steady at 8.5 percent.
At this writing, there are signs that the ratio could climb back up, but that uptick will be unrelated to transportation. Instead, it will be due to inventory carrying costs, calculated as the value of inventory multiplied by the commercial paper rate (the rate banks charge their top business customers). This year's report notes that inventory carrying costs would have been higher if not for a drop in the annualized commercial paper rate, from .13 percent in 2011 to .11 percent in 2012.
The paper rate is tied to the actions of the Federal Reserve, which has been holding down interest rates as a way to stimulate—or, as some would argue, sustain—the American economy. Back in June, Federal Reserve Chairman Ben Bernanke indicated that the central bank would stop its bond-purchasing program when the economy picks up. Taking that action will push up the commercial paper rates along with those for home mortgages and credit cards.
If the commercial paper rate rises, so will inventory carrying costs. And if overall inventory levels stay the same or increase as expected, then higher interest rates will surely bring about higher carrying costs.
And that, in my personal opinion, raises a concern. Carrying costs for business inventories constitutes one of three main components of logistics costs in the "State of Logistics Report." (The other two are transportation costs and shippers' administrative costs.) That means carrying costs are a determining factor in the judgment of logistics efficiency. Yet logistics managers have no say or control over interest rates; the Federal Reserve and credit markets influence those charges.
As the old saying goes, you can't manage what you don't control. Since logistics managers can't really manage carrying costs, then perhaps it's time to change the calculation for U.S. logistics costs to include only those elements that are under the sway of practitioners.
Editor's note: When this commentary appeared online, it elicited a number of responses from readers. To read their letters, see "Chain Reactions". If you'd like to share your own thoughts, please send an e-mail to jcooke@supplychainquarterly.com.
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.”