Maritime industry faces obstacles to efficiency, productivity
Ocean carriers, ports, and drayage truckers are confronting challenges that will ultimately affect shippers, according to speakers at a recent trade and transportation conference.
Contributing Editor Toby Gooley is a freelance writer and editor specializing in supply chain, logistics, material handling, and international trade. She previously was Editor at CSCMP's Supply Chain Quarterly. and Senior Editor of SCQ's sister publication, DC VELOCITY. Prior to joining AGiLE Business Media in 2007, she spent 20 years at Logistics Management magazine as Managing Editor and Senior Editor covering international trade and transportation. Prior to that she was an export traffic manager for 10 years. She holds a B.A. in Asian Studies from Cornell University.
Fuel mandates, potential carrier consolidation, and headaches for drayage truckers are among the key obstacles facing the maritime industry, according to speakers at the recent Coalition of New England Companies for Trade (CONECT) 23rd Annual Northeast Trade and Transportation Conference, held in Newport, R.I., in April. Such issues stand out among the many challenges that threaten the efficiency and profitability of every direct stakeholder and, ultimately, their customers, the experts said, highlighting the following:
New rules mandating low-sulfur fuel. Effective January 1, 2020, the International Maritime Organization (IMO) will require ocean carriers to use either expensive low-sulfur fuel or employ "scrubber" technology that will remove most sulfur from their ships' emissions. Compliance could add $10 billion to $15 billion annually to carriers' costs, said Gary Ferrulli, CEO of Global Transport & Logistics Consulting. As a result, carriers want to change the formula for applying fuel ("bunker") surcharges to reflect the actual average cost of fuel in specified markets, rather than basing it on quarterly projections, he said. Although shippers understand the necessity of adjusting surcharges, Ferrulli said they are concerned about the potentially sizable increase in their own costs.
In a separate presentation, keynote speaker Howard Finkel, executive vice president of trade for COSCO Container Lines Americas Inc., identified potential roadblocks to implementation of the IMO mandate by the deadline. These include the possibility that there won't be enough low-sulfur fuel available, the limited number of companies that are qualified to retrofit ships with scrubbers, and the fact that not all countries allow scrubbers. Finkel said that, depending on how it affects carriers' costs, compliance with the low-sulfur requirement could "make or break" carriers' profitability in 2020.
Potential for carrier consolidation. Low freight rates and elusive profits raise the specter of carrier mergers, acquisitions, and bankruptcies. COSCO's Finkel said he does not foresee any mergers or bankruptcies among major container carriers right now, but noted that any near-term acquisitions would likely involve smaller regional carriers. If carriers can continue to keep inbound and outbound capacity in reasonable balance while successfully managing the cost impact of the low-sulfur mandate, then stability is likely, he said.
Ferrulli noted that carriers on the trans-Pacific lanes have been managing capacity by withdrawing ships and sailings. Rates are about $100 higher than they were at the same point in 2018, he said, noting that his clients' service-contract rates are about 7 percent to 15 percent higher than they were last year. He cautioned that some carriers will be taking delivery of bigger ships in 2020 and 2021, which could make overcapacity an issue again. Ferrulli also questioned the financial viability of some Asian carriers that are subsidized by their national governments and therefore don't have to worry much about profits—a "flawed business model" that is not sustainable, he said. He also predicted changes in Europe: if the European Union lets exemptions that allow carriers to operate joint services and alliances in European trade lanes expire next year, "you are going to see [some] carriers in those agreements disappear," he said. His advice to shippers: Read carriers' financials carefully, understand the implications of working with service providers that consistently lose money, and have a plan to manage the disruption that will arise if carriers merge or go out of business.
Constraints on drayage truckers' productivity. The majority of drayage truckers—the carriers that shippers rely on to pick up and drop-off loaded and empty containers—are independent contractors. Others are small, local motor carriers, and some are larger regional networks. This segment of the transportation industry is highly fragmented; the 10 largest drayage carriers represent just 8 percent of total capacity, according to David McLaughlin, chief operating officer of one of those companies, RoadOne IntermodaLogistics, who addressed productivity concerns in this sector during a separate panel discussion.
Shippers typically pay drayage carriers a set rate per container. To make a living, drivers need to handle multiple round-trips a day. But congestion at some seaport and intermodal terminals and, once they get in the gate, difficulties in getting container chassis, mean that truckers serving those facilities spend too much of their day waiting in lines. This situation was exacerbated late last year and early in 2019, especially on the West Coast, when backlogs developed as shippers scrambled to bring in as many containers as possible before higher tariffs on Chinese goods went into effect. In addition, McLaughlin said, the giant ships that have increased the numbers of containers ports must handle at one time have hurt drayage productivity by contributing to congestion, delays, and chassis shortages at ports and off-dock intermodal ramps. In a bid to reduce congestion, some container terminals have moved chassis off dock, adding an additional, time-consuming stop for drivers, he added.
According to McLaughlin, the federally mandated hours-of-service (HOS) limitations on the number of hours drivers can work in a day are also having a negative impact on drayage truckers' productivity. He estimated that the drayage industry is seeing a 10 percent decline in productivity, and thus fewer container "turns" per day, as a result of compliance with the regulations. Meanwhile, railroads have been reducing the number of intermodal terminals they operate. As a result, drivers in some areas have to travel further to pick up and drop off containers, which he said reduces the number of trips they can make in a day. With big companies like Amazon, Uber, and Lyft "sucking away" drivers, sometimes at "double the rates that drayage companies can offer," already high driver turnover rates are climbing, and recruiting is becoming increasingly difficult, he said. Taken together, several speakers agreed, these challenges suggest that a shortage of drayage capacity may be in the offing.
The North American robotics market saw a decline in both units ordered (down 7.9% to 15,705 units) and revenue (down 6.8% to $982.83 million) during the first half of 2024 compared to the same period in 2023, as North American manufacturers faced ongoing economic headwinds, according to a report from the Association for Advancing Automation (A3).
“Rising inflation and borrowing costs have dampened spending on robotics, with many companies opting to delay major investments,” said Jeff Burnstein, president, A3. “Despite these challenges, the push for operational efficiency and workforce augmentation continues to drive demand for robotics in industries such as food and consumer goods and life sciences, among others. As companies navigate labor shortages and increased production costs, the role of automation is becoming ever more critical in maintaining global competitiveness.”
The downward trend was led by weakness in automotive manufacturing, which traditionally leads the charge in buying robots. In the first half of 2024, automotive OEMs ordered 4,159 units (up 14.4%) but generated revenue of $259.96 million (down 12.0%). The Automotive Components sector was even worse, orders 3,574 units (down 38.8%) for $191.93 million in revenue (down 27.3%). Declines also happened in the Semiconductor & Electronics/Photonics sector and the Plastics & Rubber sector.
On the positive side, Food & Consumer Goods companies ordered 1,173 units (up 85.6%) for $62.84 million in revenue (up 56.2%). This growth reflects the increasing reliance on robotics for efficiency in food processing and packaging as companies seek to address labor shortages and rising costs, A3 said. And the Life Sciences industry ordered 1,007 units (up 47.9%) for revenue of $47.29 million (up 86.7%) as it continued its reliance on robotics for efficiency and precision.
Economic activity in the logistics industry expanded for the 10th straight month in September, reaching its highest reading in two years, according to the latest Logistics Managers’ Index (LMI) report, released this week.
The LMI registered 58.6, up more than two points from August’s reading and its highest level since September 2022.
The LMI is a monthly measure of business activity across warehousing and transportation markets. A reading above 50 indicates expansion, and a reading below 50 indicates contraction.
The September data is proof the industry is “back on solid footing” according to the LMI researchers, who pointed to expanding inventory levels driven by a long-expected restocking among retailers gearing up for peak-season demand. That shift is also reflected in higher rates of both warehousing and transportation prices among retailers and other downstream firms—a signal that “retail supply chains are whirring back into motion” for peak.
“The fact that peak season is happening at all should be a bit of a relief for the logistics industry—and economy as a whole—since we have not really seen a traditional seasonal peak since 2021,” the researchers wrote. “… or possibly even 2019, if you don’t consider 2020 or 2021 to be ‘normal.’”
The East Coast dock worker strike earlier this week threatened to complicate that progress, according to LMI researcher Zac Rogers, associate professor of supply chain management at Colorado State University. Those fears were eased Thursday following a tentative agreement between the union and port operators that would put workers at dozens of ports back on the job Friday.
“We will have normal peak season demand—our first normal seasonality year in the 2020s,” Rogers said in a separate interview, noting that the port of New York and New Jersey had its busiest month on record this past July. “Inventories are moving now, downstream. That, to me, is an encouraging sign.”
The LMI is a monthly survey of logistics managers from across the country. It tracks industry growth overall and across eight areas: inventory levels and costs; warehousing capacity, utilization, and prices; and transportation capacity, utilization, and prices. The report is released monthly by researchers from Arizona State University, Colorado State University, Rochester Institute of Technology, Rutgers University, and the University of Nevada, Reno, in conjunction with the Council of Supply Chain Management Professionals (CSCMP).
Dockworkers at dozens of U.S. East and Gulf coast ports are returning to work tonight, ending a three-day strike that had paralyzed the flow of around 50% of all imports and exports in the United States during ocean peak season.
The two groups “have reached a tentative agreement on wages and have agreed to extend the Master Contract until January 15, 2025 to return to the bargaining table to negotiate all other outstanding issues. Effective immediately, all current job actions will cease and all work covered by the Master Contract will resume,” the joint statement said.
Talks had broken down over the union’s twin demands for both pay hikes and a halt to increased automation in freight handling. After the previous contract expired at midnight on September 30, workers made good on their pledge to strike, and all activity screeched to a halt on Tuesday, Wednesday, and Thursday this week.
Business groups immediately sang the praises of the deal, while also sounding a note of caution that more work remains.
The National Retail Federation (NRF) cheered the short-term contract extension, even as it urged the groups to forge a longer-lasting pact. “The decision to end the current strike and allow the East and Gulf coast ports to reopen is good news for the nation’s economy,” NRF President and CEO Matthew Shay said in a release. “It is critically important that the International Longshoremen’s Association and United States Maritime Alliance work diligently and in good faith to reach a fair, final agreement before the extension expires. The sooner they reach a deal, the better for all American families.”
Likewise, the Retail Industry Leaders Association (RILA) said it was relieved to see positive progress, but that a final deal wasn’t yet complete. “Without the specter of disruption looming, the U.S. economy can continue on its path for growth and retailers can focus on delivering for consumers. We encourage both parties to stay at the negotiating table until a final deal is reached that provides retailers and consumers full certainty that the East and Gulf Coast ports are reliable gateways for the flow of commerce.”
And the National Association of Manufacturers (NAM) commended the parties for coming together while also cautioning them to avoid future disruptions by using this time to reach “a fair and lasting agreement,” NAM President and CEO Jay Timmons said in an email. “Manufacturers are encouraged that cooler heads have prevailed and the ports will reopen. By resuming work and keeping our ports operational, they have shown a commitment to listening to the concerns of manufacturers and other industries that rely on the efficient movement of goods through these critical gateways,” Timmons said. “This decision avoids the need for government intervention and invoking the Taft-Hartley Act, and it is a victory for all parties involved—preserving jobs, safeguarding supply chains, and preventing further economic disruptions.”
Supply chain planning (SCP) leaders working on transformation efforts are focused on two major high-impact technology trends, composite AI and supply chain data governance, according to a study from Gartner, Inc.
"SCP leaders are in the process of developing transformation roadmaps that will prioritize delivering on advanced decision intelligence and automated decision making," Eva Dawkins, Director Analyst in Gartner’s Supply Chain practice, said in a release. "Composite AI, which is the combined application of different AI techniques to improve learning efficiency, will drive the optimization and automation of many planning activities at scale, while supply chain data governance is the foundational key for digital transformation.”
Their pursuit of those roadmaps is often complicated by frequent disruptions and the rapid pace of technological innovation. But Gartner says those leaders can accelerate the realized value of technology investments by facilitating a shift from IT-led to business-led digital leadership, with SCP leaders taking ownership of multidisciplinary teams to advance business operations, channels and products.
“A sound data governance strategy supports advanced technologies, such as composite AI, while also facilitating collaboration throughout the supply chain technology ecosystem,” said Dawkins. “Without attention to data governance, SCP leaders will likely struggle to achieve their expected ROI on key technology investments.”
The U.S. manufacturing sector has become an engine of new job creation over the past four years, thanks to a combination of federal incentives and mega-trends like nearshoring and the clean energy boom, according to the industrial real estate firm Savills.
While those manufacturing announcements have softened slightly from their 2022 high point, they remain historically elevated. And the sector’s growth outlook remains strong, regardless of the results of the November U.S. presidential election, the company said in its September “Savills Manufacturing Report.”
From 2021 to 2024, over 995,000 new U.S. manufacturing jobs were announced, with two thirds in advanced sectors like electric vehicles (EVs) and batteries, semiconductors, clean energy, and biomanufacturing. After peaking at 350,000 news jobs in 2022, the growth pace has slowed, with 2024 expected to see just over half that number.
But the ingredients are in place to sustain the hot temperature of American manufacturing expansion in 2025 and beyond, the company said. According to Savills, that’s because the U.S. manufacturing revival is fueled by $910 billion in federal incentives—including the Inflation Reduction Act, CHIPS and Science Act, and Infrastructure Investment and Jobs Act—much of which has not yet been spent. Domestic production is also expected to be boosted by new tariffs, including a planned rise in semiconductor tariffs to 50% in 2025 and an increase in tariffs on Chinese EVs from 25% to 100%.
Certain geographical regions will see greater manufacturing growth than others, since just eight states account for 47% of new manufacturing jobs and over 6.3 billion square feet of industrial space, with 197 million more square feet under development. They are: Arizona, Georgia, Michigan, Ohio, North Carolina, South Carolina, Texas, and Tennessee.
Across the border, Mexico’s manufacturing sector has also seen “revolutionary” growth driven by nearshoring strategies targeting U.S. markets and offering lower-cost labor, with a workforce that is now even cheaper than in China. Over the past four years, that country has launched 27 new plants, each creating over 500 jobs. Unlike the U.S. focus on tech manufacturing, Mexico focuses on traditional sectors such as automative parts, appliances, and consumer goods.
Looking at the future, the U.S. manufacturing sector’s growth outlook remains strong, regardless of the results of November’s presidential election, Savills said. That’s because both candidates favor protectionist trade policies, and since significant change to federal incentives would require a single party to control both the legislative and executive branches. Rather than relying on changes in political leadership, future growth of U.S. manufacturing now hinges on finding affordable, reliable power amid increasing competition between manufacturing sites and data centers, Savills said.