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Going the Extra Mile

AST

AST President Billy Kingston, center, with his sons, Chris, left, vice president of International Services, and Tim, vice president of Domestic Services.

Billy Kingston says the global shipping business has historically been an ultra-challenging, often-misunderstood sector of the economy, one defined by heavy competition, demanding customers, unseen twists and turns, and a landscape that can, and does, change quickly and often.

And that was before COVID and the manner in which it eventually turned the supply chain on its ear, inflation, the war in Ukraine, higher tariffs on many goods, a workforce crisis, soaring fuel prices, remote work, and everything else that has happened over the past few years.

Summing it all up, Kingston, president of All States Transport, better known as AST, said this has certainly been a tumultuous and very difficult time for this industry, one that AST has withstood because of all it can bring to the table, especially (in his case) a half-century of experience, but also a deep, talented core of employees, connections around the globe, and, most importantly, a commitment to delivering for customers and going the extra mile.

Those are both industry terms, sort of, but they help explain why AST, a domestic freight broker and international freight forwarder, terms that are self-explanatory, is able to stand out in a sea of competitors, both domestically and globally, in a business where firms are tasked with getting things from here to there — or there to here — in a timely fashion.

Elaborating, he said the keys to success for any company in this business are flexibility, the ability to move quickly and effectively, establishing trust with customers, and amassing a track record for success in delivering for clients, in every sense of that phrase.

“We arrange for transportation of goods to and from our customers anywhere in the world,” said Kingston, offering a simple explanation for work that is anything but simple. “The domestic side of the business is how we started way back, and that side of it is very active. The international side has been growing over the years and doing well; we move freight internationally by land and water.”

“We have so many great customers … if you’re upfront with them, they’re going to be upfront with you. That way, you can work through things, because transportation is nothing if not problems that have to be worked through.”

“It’s a rugged business with real issues, and we live them,” continued Kingston, who leads a staff of 20 along with his sons, Chris, vice president of International Services, and Tim, vice president of Domestic Services. “Through all of the ups and downs of the economy, fuel issues, and supply-chain woes over the past few years, it has just been very challenging.

“For us as a company, it has been our best period of time, business-wise,” he went on. “But it’s also been the most difficult to operate in.”

In a wide-ranging interview, the Kingstons pulled back the curtain on an industry that few outside really know, one that is settling back into something approaching what was happening before the pandemic, although no one came close to using the word ‘normal.’

To put things in perspective, Billy Kingston said that, before the pandemic, the cost for a shipping container coming in from China was $4,000 to $5,000. At the height of the pandemic, that cost had soared to $25,000 to $30,000.

“The spike was just amazing, and at that price, you were bidding, and hoping, to be able to get a container, and then hoping to get a spot on a ship to come this way,” he said, adding that the impact of the many issues within the shipping industry on inflation and the general economy cannot be understated.

 

Train of Thought

As he talked about the global shipping business, Chris noted that, like other sectors of the economy, this one has a language all its own, with an alphabet soup of acronyms.

These include TL (truckload), LTL (less than truckload), DAP (delivered at place), DPU (delivered at place unloaded), and myriad others.

Learning this language and helping clients understand it is just one of the many nuances of the global shipping business, said Billy, who got his start in it back in the mid-’70s, working in sales for several different national trucking companies as well as an international freight forwarder.

After working in the business for many years, he decided he knew it well enough, and had enough solid connections, to strike out on his own. He started All States Transport in the basement of his home in the Forest Park section of Springfield in 1985.

The global shipping industry is highly competitive and ever-changing, and the pandemic only added several additional layers of challenge.

For the first year or so, it was a one-person operation that eventually moved into a small office in Market Square in downtown Springfield, adding employees as it continued to grow and expand its portfolio of clients, many of which have stayed with the company through its history.

The company had a few different homes — as well as its own small trucking company, which it operated out of property on Avocado Street in Springfield for several years — before settling into its current location on East Columbus Avenue, the former home to the Leonard Gallery and Sam’s Glass.

For the past 15 years, AST has also operated a small office in Miami. At one time, it also housed a trucking operation there, but that, like the one in Springfield, became difficult to manage. So, in both locations, the company has returned to its roots — and its routes — as a freight broker and forwarder.

“When the pandemic hit, because there was so much uncertainty in the general economy, you saw companies all over the world closing down and canceling orders that had been in place for a long time.”

As he explained the operation, Billy said that, in a nutshell, AST goes about finding global shipping solutions for its many kinds of clients, most of them manufacturers. About 80% of the company customers are based in Western and Central Mass., Northern Connecticut, and Rhode Island, he said, with the rest spread out over the country.

As a broker, AST will work with a client to secure the shipping of goods to or from their business. To do so, it works with trucking outfits across the region and around the country, as well as rail-service providers and sea and air carriers. What separates the many (as in thousands) of competitors in this field is their ability to make and maintain connections with carriers, know and understand the market, move quickly (many clients want same-day service), and deliver on both price and quality of service.

And all this requires an experienced, talented workforce. “You need a staff that is familiar with the marketplace and has all the tools and technology they need to succeed,” Billy explained. “It’s a fast-moving, time-sensitive, rate-conscious industry — that’s what it’s about.

“We have other customers that we’ve done business with for years and years … they don’t ask us for rate on every load,” he went on. “In many cases, we have the ability with those customers to move up or down as we need to, to service their needs and ours. And that only comes from years of good faith and years of trust, built up between us and our customers because they know that if we need to add extra dollars to a rate, there’s a good reason for that. They also know that if we can reduce that rate, we’re going to do that, and we do this as often as we can.”

Beyond rates, successful freight brokers and forwarders need to have a thorough understanding of the players in the shipping field, where they operate, and how, said Tim Kingston, adding that AST works with trucking companies across the country.

“And we need to, because trucking companies, by their nature, and by their history, generally service certain sections of the country,” he explained. “Some will go anywhere, but a lot of them carve out a part of the country that they want to service for their business needs. You learn those, and when you have freight moving to South Carolina, you know where to start.”

Chris agreed, and said one constant for the company through the years has been to apply an established set of values and principles and to effectively partner with clients and communicate with them — another must in this business.

“It’s a super-competitive, time-sensitive, money-sensitive industry that changes on a dime in many cases. You need to have a staff that’s dedicated; you need to have a staff that’s used to hearing the word ‘no,’ because they hear it a lot.”

“If you have good news for a customer, give them good news; if you have bad news, something’s gone wrong, let them know early, communicate that, and try to work through problems,” he said. “We have so many great customers … if you’re upfront with them, they’re going to be upfront with you. That way, you can work through things, because transportation is nothing if not problems that have to be worked through.

“Sure, 60% of your loads are going to go without a hitch,” he went on. “The other 40% … that’s where the real work is, so we try to apply the same values across all our different sectors.”

 

Plane Speaking

This combination of experience, built-up trust, and ability to adjust to rapidly — and often profoundly — changing conditions, has enabled AST to not only thrive for the past four decades, but also persevere through this recent, and ongoing, period of heavy turbulence.

Indeed, as noted earlier, this challenging business has become more so — make that even more so — over the past several years with the profound changes to the landscape brought on by the pandemic.

At the top of this list were supply-chain issues that could only be described as historic, said all three Kingstons, noting that the industry was seeing explosive surges in prices for shipping containers and backups at ports around the globe. It didn’t happen overnight, but almost.

Billy explained how it all happened. “When the pandemic hit, because there was so much uncertainty in the general economy, you saw companies all over the world closing down and canceling orders that had been in place for a long time,” he said. “Manufacturers then began cutting back, as well as transportation companies — steamship lines parked vessels all over the world because the demand wasn’t there. No one had an idea when it was going to come back, and that really kicked off the fluctuation in the supply chain.”

Chris agreed, and noted that, three or four months into the pandemic, an array of colliding forces made the situation much worse.

“A lot of people were at home, and they weren’t doing the things they always did in terms of discretionary income,” he explained. “People were at home, and they bought many more things than they normally buy. And then, you had the stimulus programs, which gave people more spending money. Then … you had a lot less international shipping capacity, but a giant surge in demand. Meanwhile, you had empty containers in the wrong places that took forever to get repositioned.

All this created a messed-up supply-and-demand curve, which would have resulted in a container coming in from China for $25,000, just for the cost of the container, never mind the tariff,” he went on. “It created a lopsided supply-and-demand curve, which pushed prices out of sight.”

This phenomenon, which has eased considerably in recent months but is still an issue, is just one of many that has contributed to this being what is considered the most volatile period ever for an industry known for volatility.

On top of everything else, the global shipping industry, like virtually every other sector, has been impacted by an ongoing workforce crisis, Billy said, adding, again, that success in this business is directly related to the quality and consistency of the people doing the work.

“It’s a super-competitive, time-sensitive, money-sensitive industry that changes on a dime in many cases,” he told BusinessWest. “You need to have a staff that’s dedicated; you need to have a staff that’s used to hearing the word ‘no,’ because they hear it a lot; you need to have a staff that understands customer needs and understands which customers can be a little more flexible and more reasonable at times, and which customers can’t be because of the nature of their business. They need to be thick-skinned because it’s not always pretty.”

Indeed, many in this business, including AST, are looking for help right now, he went on, adding that, over the past several years, and essentially from the beginning, AST has made itself into what he considers a good place to work — and grow.

“In this environment, especially, we take care of our staff in every possible way,” he said. “We have some benefits that are quite outstanding, especially for a company our size, and we’re proud of that. As a result, generally, our people are with us for a very long time; very few people leave, and we’re proud of that, too.”

Elaborating, he said that, because of tight deadlines and the need to deliver, there is pressure on employees, something the company’s managers work to alleviate as best they can.

“We have some fun every day — at different times, you never know when it’s going to happen,” he went on. “And there are days when the fun doesn’t come very quickly or very often because you’re right to the wall, morning ’til night. But we try to lighten things up when we can and in whatever way we can.”

Manufacturing

Making Change

 

The manufacturing tech industry is building back fast, undeterred by significant labor and supply-chain challenges. To maintain this momentum, manufacturers should navigate elevated risks while advancing sustainability priorities. That’s the takeaway, at any rate, from a recent Deloitte report exploring five manufacturing industry trends that can help organizations turn risks into advantages and capture growth.

It’s unusual to see positive economic indicators paired with historic labor and supply-chain challenges. But this is the trajectory for the U.S. manufacturing industry in 2022 emerging from the pandemic. The recovery gained momentum in 2021 on the heels of vaccine rollout and rising demand. As industrial production and capacity utilization surpassed pre-pandemic levels this year, strong increases in new orders for all major subsectors signal growth continuing in 2022.

However, optimism around revenue growth is held in check by caution from ongoing risks. Workforce shortages and supply-chain instability are reducing operational efficiency and margins. Business agility can be critical for organizations seeking to operate through the turbulence from an unusually quick economic rebound — and to compete in the next growth period. As leaders look not only to defend against disruption but strengthen their offense, our 2022 manufacturing-industry outlook examines five important trends to consider for manufacturing playbooks in the year ahead.

 

1. Preparing for the future of work could be critical to resolving current talent scarcity. Record numbers of unfilled jobs are likely to limit higher productivity and growth in 2022, and last year we estimated a shortfall of 2.1 million skilled jobs by 2030. To attract and retain talent, manufacturers should pair strategies such as reskilling with a recasting of their employment brand.

Shrinking the industry’s public perception gap by making manufacturing jobs a more desirable entry point could be critical to meeting hiring needs in 2022. Engagement with a wider talent ecosystem of partners to reach diverse, skilled talent pools can help offset the recent wave of retirements and voluntary exits.

Manufacturing executives may also need to balance goals for retention, culture, and innovation. As flexible work is taking root in offices, manufacturers should explore ways to add flexibility across their organizations in order to attract and retain workers. Organizations that can manage through workforce shortages and a rapid pace of change today can come out ahead.

 

2. Manufacturers are remaking supply chains for advantage beyond the next disruption. Supply-chain challenges are acute and still unfolding. There’s no mistaking that manufacturers face near-continuous disruptions globally that add costs and test abilities to adapt. Purchasing manager reports continue to reveal systemwide complications from high demand, rising costs of raw materials and freight, and slow deliveries in the U.S.

Transportation challenges are likely to continue in 2022 as well, including driver shortages in trucking and congestion at U.S. container ports. As demand outpaces supply, higher costs are more likely to be passed on to customers.

Root causes for extended U.S. supply-chain instability may include overreliance on low inventories, rationalization of suppliers, and hollowing out of domestic capability. Supply-chain strategies in 2022 are expected to be multi-pronged. Digital supply networks and data analytics can be powerful enablers for more flexible, multi-tiered responses to disruptions.

 

3. Acceleration in digital technology adoption could bring operational efficiencies to scale. Manufacturers looking to capture growth and protect long-term profitability should embrace digital capabilities from corporate functions to the factory floor. Smart factories, including greenfield and brownfield investments for many manufacturers, are viewed as one of the keys to driving competitiveness.

More organizations are making progress and seeing results from more connected, reliable, efficient, and predictive processes at the plant. Emerging and evolving use cases can continue to scale up from isolated in-house technology projects to full production lines or factories, given the right mix of vision and execution.

U.S. manufacturers have room to run with advanced manufacturing compared to many competitors globally. Advanced global ‘lighthouse’ factories showcase the art of the possible in bringing smart manufacturing to scale. Investment in robots, cobots, and artificial intelligence can continue to transform operations. Foundational technologies such as cloud computing enable computational power, visibility, scale, and speed. Industrial 5G deployment may also expand in 2022 along with advances in technology and use cases.

 

4. Rising cybersecurity threats are leading the industry to new levels of preparedness. High-profile cyberattacks across industries and governments in the past year have elevated cybersecurity as a risk-management essential for most executives and boards. Surging threats during the pandemic added to business risk for manufacturers in the crosshairs for ransomware.

An expanding attack surface from the connection of operational technology (OT), information technology (IT), and external networks requires more controls. Legacy systems and technology weren’t purpose-fit for today’s sophisticated network challenges. Now, remote-work vulnerabilities leave manufacturers even more susceptible to breaches.

Manufacturers should look not only at their cyberdefenses, but also at the resiliency of their business in the event of a cyberattack. Cybercriminals can cause harm beyond intellectual-property theft and financial losses, using malware that now ties in AI and cryptocurrencies. They can also shut down operations and disrupt entire supplier networks, compromising safety as well as productivity. A patchwork of regulations for different industries could be consolidated under the current administration’s ‘whole-of-nation’ approach to protect critical infrastructure. The potential for additional oversight is likely to prompt more industrials to rethink preparedness for crisis response.

 

5. Manufacturers are likely to bring more resources and rigor to advancing sustainability. The fast rise of environmental, social, and governance (ESG) factors is redefining and elevating sustainability in manufacturing as never before. Cost of capital can be tied to ratings on ESG, making it a priority for organizational financial health and competitiveness. Expectations for reporting on diversity, equity, and inclusion metrics in manufacturing will likely continue to rise. Board diversity, while progressing slowly, is also showing some momentum. To attract talent and appeal to workforce expectations, most manufacturers are making ESG efforts more visible.

Depending on a manufacturer’s end markets, environmental accountability is increasingly a focus. To develop and deliver against net-zero or carbon-neutral goals, more organizations are dedicating or redesigning sustainability roles and initiatives and quantifying efforts and results around energy consumption. And the fast-evolving ESG landscape may require close monitoring in 2022 for manufacturers.

Many organizations are complying voluntarily within a complex network of reporting regulations, ratings, and disclosure frameworks. But regulators globally are also moving toward requiring disclosure for more non-financial metrics. Proactive approaches may help manufacturers stay ahead of the change and create competitive advantage.

Coronavirus

Supply Chain of Events

Supply chain.

That’s a two-word phrase that had rarely made its way into the lexicon of most area residents before the COVID-19 pandemic; it was generally assumed that the shelves in the stores would be crammed with product — because they always had been.

But in a year when there have been shortages of cleaning supplies, surgical masks, beef, fish, hair coloring, paper towels, ice cream, rice, frozen pizza, and, yes, toilet paper — a product that has become a metaphor for a crisis — people can no longer take supply chain, and full shelves, for granted.

This has been a learning experience — on a number of levels.

So too for those who work to keep the shelves stocked. For them, it’s a time of relationship building, finding new ways of doing things, and providing ongoing proof that, while the supply chain has been bent — severely and repeatedly — it hasn’t, in their minds, been broken.

“The supply chain has definitely been tested through all this, and there have been shortages of some things, as everyone knows,” said Michael D’Amour, chief operating officer at Springfield-based Big-Y, the fourth-generation, family-owned grocery chain. “But, overall, I think this crisis has shown just how resilient the supply chain is.”

 

Michael D’Amour

Michael D’Amour

“The supply chain has definitely been tested through all this, and there have been shortages of some things, as everyone knows. But, overall, I think this crisis has shown just how resilient the supply chain is.”

 

Doug Baker, vice president of Industry Relations for the Food Marketing Institute, (FMI) agreed.

“Almost weekly we’re getting back numbers, and we’re still seeing double-digit growth across many categories — and you can’t have double-digit growth if inventory is not available,” he said, referring to specific product lines ranging from cleaning supplies to frozen foods. “It’s just a matter of matching inventory with consumer demand, and that’s been the challenge.

“And that’s why we’ve seen shortages — because that inventory output hasn’t been able to rise to the level of consumer demand,” he went on, adding that recent numbers show a slowing of demand that is giving many producers at least a chance to catch up.

In March, on average, the industry was seeing 35% to 40% increases in overall sales volume, Baker said, while in late May, the number was closer to 20% to 25%.

“We’re seeing sales slow, which is helpful because it allows the supply chain to catch up to an extent,” he explained. “But we also have to understand that those are still pretty significant increases, and we’re not going to go back to pre-COVID days, because the public still has yet to engage in a livelihood that they engaged in before the pandemic, and that’s based on where you see them spending their food dollar.”

D’Amour agreed, noting that, as May turned to June, a good number of people were still in something approaching lockdown mode. They were eating most meals at home because restaurants were only open for takeout. They were also still working at home and, therefore, eating lunch at home. Meanwhile, children are home from school, and college students are home as well. This all adds up to people buying more at the supermarket.

As phase 2 of Gov. Charlie Baker’s reopening plan takes effect on June 8, restaurants will be opening for curbside dining, and preschools and day camps will be reopening. And as more and more people go back to their offices — the ones they left in March for space on their dining room table — the ratio of food dollars spent out of the home will start to rise higher.

How long it will take to reach pre-COVID levels — when 54 cents of each dollar was spent outside the home — remains to be seen, said Baker. However, what is certain is that the situation is fluid at best and it could change in a hurry if cases start to surge, a second wave arrives, and people start spending more time working — and eating — at home.

Doug Baker

Doug Baker

“We’re seeing sales slow, which is helpful because it allows the supply chain to catch up to an extent. But we also have to understand that those are still pretty significant increases, and we’re not going to go back to pre-COVID days, because the public still has yet to engage in a livelihood that they engaged in before the pandemic, and that’s based on where you see them spending their food dollar.”

Meanwhile, this new normal has essentially forced chains like Big Y to forge new alliances with suppliers, said D’Amour, noting that as restaurants, colleges, and schools of all kinds closed earlier this year, this created an enormous surplus of inventory, but put the demand on grocery stores, while also creating an opportunity to redeploy goods and resources to grocery retail to meet demand and reduce waste.

One such alliance, one that typifies how suppliers and grocers are working together to forge solutions, involves Little Leaf Farms in Shirley, a local partner and grower of lettuce that saw demand decline dramatically as schools and restaurants closed a few months back and was looking for new opportunities to sell product and reduce the kind of waste that was seen almost nightly on major news broadcasts.

“They’re one example of so many local partners who have sat down with us and worked to figure out how to maximize business between us and keep their stuff growing and moving through the pipeline when the restaurants were shut down,” D’Amour explained. “We worked with them on supply and hotter deals and pricing to keep it moving through the grocery channels.”

For this issue, BusinessWest talked with several players involved with supply chain about the lessons learned to date and how they will help the broad food industry through the uncertain months to come.

Food for Thought

As noted earlier, the laws of supply and demand generally take care of shortages on store shelves — in normal times.

But these are not normal times, said those we spoke with. Still, those laws have applied to items like surgical masks. Hard to find only six weeks ago, they are now seemingly everywhere, and in large quantities, as a number of companies started making them — and more of them.

“Everyone’s getting into the mask business now,” Baker explained, adding quickly that it’s much easier to convert machines to make those products than it is to supply more canisters of Lysol or make more rolls of toilet paper, as simple as that might sound.

“Paper manufacturers have been putting in additional lines,” he said. “But the challenge the industry is facing now is that there two types of fiber used to make toilet paper — there’s recycled fiber and there’s virgin fiber, and with recycled fiber, the supply is low, and not every machine can be converted to use virgin fiber, so you’re going to have less output if you can’t convert.”

And sometimes, because of the pandemic, producers simply cannot meet demand.

That was the case for several weeks — although matters have improved — when it came to supplies of meat and chicken, said Baker, noting that, early on, plants were shut down temporarily. And when they reopened, to keep workers safe, production lines were altered in ways that actually slowed production.

Such specific cases help explain shortages of particular items, said those we spoke with, adding that, overall, many of the empty shelves result from unprecedented demand and panic buying that is starting to wane in many instances. But as the year continues, more lessons will certainly be learned, said D’Amour, adding that there have been plenty of learning experiences already.

Elaborating, he said that, from the beginning, those at Big Y have been watching what’s happening globally, anticipating, and “trying to get on top of things” — a phrase he would use many times — when it comes to everything from employee and customer safety to creating efficient traffic flow in the stores, to keeping items on the shelves.

This has obviously led to new policies and procedures — from the directional arrows on the floors to special hours created for seniors to the plexiglass screens at the check-out counters.

“For us, the biggest component is the people part, and that continues to be stressed by our suppliers, wholesalers, and others,” he said, adding that, while much of that panic buying and hoarding is being talked about in the past tense, the need for diligence remains, and chains like Big Y can’t let their guards down.

Getting back to the supply chain, D’Amour said it has been a struggle in some well-documented areas, but suppliers are responding by trying to increase supply and also reduce the number of overall SKUs to help put some product on the shelves.

“Where people are used to walking down the paper aisle and seeing 150 different choices of bath tissue and paper towels, now they’re seeing far fewer,” he said. “But products are coming back; we’re working with all our partners to get them back in.”

Perhaps the biggest key to providing quality service to customers during the crisis has been efforts to forge new partnerships and stronger relationships with those within the food-service industry, said D’Amour. He mentioned ongoing work with Springfield-based Performance Food Group as one example.

“They’ve done a phenomenal job working with us, working together, to figure out what food they have stuck in the pipeline that we can use,” he explained, adding that, over the past several months, PFG, as it’s called, has even helped with trucking and labor for either Big Y’s warehouse or at wholesale partners. “Most of these partnerships we’ve had have been mutually beneficial, but there are strategies and tactics that we’ve never done before; everyone’s been very open and ready to fight the battle, work together, and think of new ways to partner for the benefit of the consumers.”

Which brings him to Little Leaf Farms. Paul Sellew, owner and founder of that facility, which began operations just four years ago, said it is now part of a larger local-food movement that not only puts fresher produce on the shelves, but in many ways helps ease flow of product through the supply chain.

“People don’t realize that 95% of the leafy greens that you see in the grocery store are grown in California and Arizona,” he explained. “And when you have this global pandemic, an unprecedented situation, that puts stress on the supply chain, so imagine managing a supply chain from Selinas, California to Springfield, as opposed to my supply chain, from Devens, Mass. to Springfield.”

Little Leaf has historically seen much of its business fall into the broad category of food service — restaurants, schools, and other institutions. But with the pandemic and the sharp decline of demand on that side, the company, like many other suppliers, has shifted into retail grocery, which has been a win/win/win, for those growers, the grocers, and, ultimately, consumers.

“When you get these unprecedented events, you really want to make this region stronger and more resilient, and food is such a strong, fundamental component of that,” he went on. “And that’s why we’re so grateful for partnerships like the one we have with Big Y, which has supported us from day one.”

Overall, there is a ‘new normal’ within the grocery/food-service industry, a phrase now being heard in virtually every sector of the economy. It involves a landscape that could change quickly and profoundly depending on the pandemic and its impact.

No one really knows when there will be real light at the end of the tunnel, said D’Amour, adding that Big Y, like all those it is partnering and working with, needs to remain nimble and flexible, and continue to work in partnership with others to not only keep the shelves stocked, but also keep people safe.

Bottom Line

Summing up the past several months, those we spoke with said it’s been a challenging and in many ways difficult time, where, again, many important lessons have been learned that will serve consumers, suppliers, and retailers well in the uncertain months still to come.

“The United States is a country of abundance, and the supply chain is a beneficiary of this abundance,” Baker said. “Yes, the supply chain is strained, and some shortages will be experienced, but it’s not broken — there are not critical disruptions in the supply chain.”

The hope, and the expectation, said D’Amour, is that things will stay that way.

George O’Brien can be reached at [email protected]

Coronavirus

Supply Chain of Events

By George O’Brien

Supply chain.

That’s a two-word phrase that had rarely made its way into the lexicon of most area residents before the COVID-19 pandemic; it was generally assumed that the shelves in the stores would be crammed with product — because they always had been.

But in a year when there have been shortages of cleaning supplies, surgical masks, beef, fish, hair coloring, paper towels, ice cream, rice, frozen pizza, and, yes, toilet paper — a product that has become a metaphor for a crisis — people can no longer take supply chain, and full shelves, for granted.

This has been a learning experience — on a number of levels.

So too for those who work to keep the shelves stocked. For them, it’s a time of relationship building, finding new ways of doing things, and providing ongoing proof that, while the supply chain has been bent — severely and repeatedly — it hasn’t, in their minds, been broken.

Michael D’Amour

“The supply chain has definitely been tested through all this, and there have been shortages of some things, as everyone knows,” said Michael D’Amour, chief operating officer at Springfield-based Big-Y, the fourth-generation, family-owned grocery chain. “But, overall, I think this crisis has shown just how resilient the supply chain is.”

Doug Baker, vice president of Industry Relations for the Food Marketing Institute, (FMI) agreed.

“Almost weekly we’re getting back numbers, and we’re still seeing double-digit growth across many categories — and you can’t have double-digit growth if inventory is not available,” he said, referring to specific product lines ranging from cleaning supplies to frozen foods. “It’s just a matter of matching inventory with consumer demand, and that’s been the challenge.

Doug Baker

“And that’s why we’ve seen shortages — because that inventory output hasn’t been able to rise to the level of consumer demand,” he went on, adding that recent numbers show a slowing of demand that is giving many producers at least a chance to catch up.

In March, on average, the industry was seeing 35% to 40% increases in overall sales volume, Baker said, while in late May, the number was closer to 20% to 25%.

“We’re seeing sales slow, which is helpful because it allows the supply chain to catch up to an extent,” he explained. “But we also have to understand that those are still pretty significant increases, and we’re not going to go back to pre-COVID days, because the public still has yet to engage in a livelihood that they engaged in before the pandemic, and that’s based on where you see them spending their food dollar.”

D’Amour agreed, noting that, as May turned to June, a good number of people were still in something approaching lockdown mode. They were eating most meals at home because restaurants were only open for takeout. They were also still working at home and, therefore, eating lunch at home. Meanwhile, children are home from school, and college students are home as well. This all adds up to people buying more at the supermarket.

As phase 2 of Gov. Charlie Baker’s reopening plan takes effect on June 8, restaurants will be opening for curbside dining, and preschools and day camps will be reopening. And as more and more people go back to their offices — the ones they left in March for space on their dining room table — the ratio of food dollars spent out of the home will start to rise higher.

How long it will take to reach pre-COVID levels — when 54 cents of each dollar was spent outside the home — remains to be seen, said Baker. However, what is certain is that the situation is fluid at best and it could change in a hurry if cases start to surge, a second wave arrives, and people start spending more time working — and eating — at home.

Meanwhile, this new normal has essentially forced chains like Big Y to forge new alliances with suppliers, said D’Amour, noting that as restaurants, colleges, and schools of all kinds closed earlier this year, this created an enormous surplus of inventory, but put the demand on grocery stores, while also creating an opportunity to redeploy goods and resources to grocery retail to meet demand and reduce waste.

One such alliance, one that typifies how suppliers and grocers are working together to forge solutions, involves Little Leaf Farms in Shirley, a local partner and grower of lettuce that saw demand decline dramatically as schools and restaurants closed a few months back and was looking for new opportunities to sell product and reduce the kind of waste that was seen almost nightly on major news broadcasts.

“They’re one example of so many local partners who have sat down with us and worked to figure out how to maximize business between us and keep their stuff growing and moving through the pipeline when the restaurants were shut down,” D’Amour explained. “We worked with them on supply and hotter deals and pricing to keep it moving through the grocery channels.”

For this issue, BusinessWest talked with several players involved with supply chain about the lessons learned to date and how they will help the broad food industry through the uncertain months to come.

Food for Thought

As noted earlier, the laws of supply and demand generally take care of shortages on store shelves — in normal times.

But these are not normal times, said those we spoke with. Still, those laws have applied to items like surgical masks. Hard to find only six weeks ago, they are now seemingly everywhere, and in large quantities, as a number of companies started making them — and more of them.

“Everyone’s getting into the mask business now,” Baker explained, adding quickly that it’s much easier to convert machines to make those products than it is to supply more canisters of Lysol or make more rolls of toilet paper, as simple as that might sound.

“Paper manufacturers have been putting in additional lines,” he said. “But the challenge the industry is facing now is that there two types of fiber used to make toilet paper — there’s recycled fiber and there’s virgin fiber, and with recycled fiber, the supply is low, and not every machine can be converted to use virgin fiber, so you’re going to have less output if you can’t convert.”

And sometimes, because of the pandemic, producers simply cannot meet demand.

That was the case for several weeks — although matters have improved — when it came to supplies of meat and chicken, said Baker, noting that, early on, plants were shut down temporarily. And when they reopened, to keep workers safe, production lines were altered in ways that actually slowed production.

Such specific cases help explain shortages of particular items, said those we spoke with, adding that, overall, many of the empty shelves result from unprecedented demand and panic buying that is starting to wane in many instances. But as the year continues, more lessons will certainly be learned, said D’Amour, adding that there have been plenty of learning experiences already.

Elaborating, he said that, from the beginning, those at Big Y have been watching what’s happening globally, anticipating, and “trying to get on top of things” — a phrase he would use many times — when it comes to everything from employee and customer safety to creating efficient traffic flow in the stores, to keeping items on the shelves.

This has obviously led to new policies and procedures — from the directional arrows on the floors to special hours created for seniors to the plexiglass screens at the check-out counters.

“For us, the biggest component is the people part, and that continues to be stressed by our suppliers, wholesalers, and others,” he said, adding that, while much of that panic buying and hoarding is being talked about in the past tense, the need for diligence remains, and chains like Big Y can’t let their guards down.

Getting back to the supply chain, D’Amour said it has been a struggle in some well-documented areas, but suppliers are responding by trying to increase supply and also reduce the number of overall SKUs to help put some product on the shelves.

“Where people are used to walking down the paper aisle and seeing 150 different choices of bath tissue and paper towels, now they’re seeing far fewer,” he said. “But products are coming back; we’re working with all our partners to get them back in.”

Perhaps the biggest key to providing quality service to customers during the crisis has been efforts to forge new partnerships and stronger relationships with those within the food-service industry, said D’Amour. He mentioned ongoing work with Springfield-based Performance Food Group as one example.

“They’ve done a phenomenal job working with us, working together, to figure out what food they have stuck in the pipeline that we can use,” he explained, adding that, over the past several months, PFG, as it’s called, has even helped with trucking and labor for either Big Y’s warehouse or at wholesale partners. “Most of these partnerships we’ve had have been mutually beneficial, but there are strategies and tactics that we’ve never done before; everyone’s been very open and ready to fight the battle, work together, and think of new ways to partner for the benefit of the consumers.”

Paul Sellew

Which brings him to Little Leaf Farms. Paul Sellew, owner and founder of that facility, which began operations just four years ago, said it is now part of a larger local-food movement that not only puts fresher produce on the shelves, but in many ways helps ease flow of product through the supply chain.

“People don’t realize that 95% of the leafy greens that you see in the grocery store are grown in California and Arizona,” he explained. “And when you have this global pandemic, an unprecedented situation, that puts stress on the supply chain, so imagine managing a supply chain from Selinas, California to Springfield, as opposed to my supply chain, from Devens, Mass. to Springfield.”

Little Leaf has historically seen much of its business fall into the broad category of food service — restaurants, schools, and other institutions. But with the pandemic and the sharp decline of demand on that side, the company, like many other suppliers, has shifted into retail grocery, which has been a win/win/win, for those growers, the grocers, and, ultimately, consumers.

“When you get these unprecedented events, you really want to make this region stronger and more resilient, and food is such a strong, fundamental component of that,” he went on. “And that’s why we’re so grateful for partnerships like the one we have with Big Y, which has supported us from day one.”

Overall, there is a ‘new normal’ within the grocery/food-service industry, a phrase now being heard in virtually every sector of the economy. It involves a landscape that could change quickly and profoundly depending on the pandemic and its impact.

No one really knows when there will be real light at the end of the tunnel, said D’Amour, adding that Big Y, like all those it is partnering and working with, needs to remain nimble and flexible, and continue to work in partnership with others to not only keep the shelves stocked, but also keep people safe.

Bottom Line

Summing up the past several months, those we spoke with said it’s been a challenging and in many ways difficult time, where, again, many important lessons have been learned that will serve consumers, suppliers, and retailers well in the uncertain months still to come.

“The United States is a country of abundance, and the supply chain is a beneficiary of this abundance,” Baker said. “Yes, the supply chain is strained, and some shortages will be experienced, but it’s not broken — there are not critical disruptions in the supply chain.”

The hope, and the expectation, said D’Amour, is that things will stay that way.

George O’Brien can be reached at [email protected]