OM in the News: The Megaship Capacity Disaster

In 2006, the Emma Maersk left her shipyard. The length of 4 soccer fields, Emma was far larger and more expensive than any container ship ever before. She was a bet on globalization: By transporting a container more cheaply than any other vessel afloat, she and her 6 sister ships were expected to stimulate even faster growth in international trade, lowering the cost of moving goods through the supply chains that had reshaped the global economy. But the opposite occurred. Emma and the even larger ships that followed in her wake became a nightmare.

Container ships are the workhorses of globalization. Operating on regular schedules— an identical vessel departs Shanghai every Wednesday, stops in Singapore 9 days later and arrives in Antwerp 5 weeks hence, with tight connections to barges and freight trains—intermodal container transport gave manufacturers and retailers the confidence to plan tightly organized long-distance supply chains. Emma and her sisters’ size was expected to give shipping an immense cost advantage. Maersk forecast in 2006 that the demand for container shipping would double by 2016.

The container ship Emma Maersk in Hamburg

But the boom never occurred. Instead, international trade collapsed in 2008-09, and when it picked up again, its growth was far weaker than before. By the early 2010s, there simply weren’t enough container loads to fill all the new capacity, wiping out the cost advantages of larger vessels. And discharging and reloading megaships took longer as well, with more boxes to put off and on, while giant shoreside cranes needed to reach a greater distance to pick up a container. Thousands more boxes multiplied by more handling time per box added days to a port call. Delays were legion.

Once, container ships would have been able to make up those delays en route. But to save fuel and reduce greenhouse gas emissions, vessels must now travel at 17-18 knots instead of 24-25 previously, adding several days to a long ocean voyage. By 2018, 30% of the ships leaving China departed late.

“With proper accounting,” concludes The Wall Street Journal (Oct. 24-25, 2020), “the globalization of manufacturers’ supply chains no longer seems such a bargain.”

Classroom discussion questions:

  1. How would the land side of international logistics be impacted by this issue?
  2. What capacity strategy best fits shipping companies now? (Hint: see Figure S7.6 in your Heizer/Render/Munson text)

OM in the News: Megaships as Part of the Supply Chain

There may be a (post) recession here in the US, but as Asian trade swells, the demand for massive container ships is booming. “Megavessels–ships longer than the 1,063 foot-high Eiffel Tower”, writes today’s Businessweek , “are in demand again”. Shipping lines are preparing for the 2014 completion of the $5.25 billion expansion of the Panama Canal, plus the recovery of global trade. It takes about 3 years to build a new “big” ship–one that can move more than 8,000 20-foot containers. The Canal can only handle ships with up to 5,000 containers now, but will accomodate vessels with up to 12,600 containers in 3 years.

Global trade is expected to expand 11% percent this year and 7% next year, recovering from an 11% drop in 2009. Currently there are 61 ships in operation that can carry more than 6,000 boxes, with 144 more on order to begin service starting in 2014. All except 12 come from South Korean shipyards, especially leader Daewoo Shipbuilding, in Seoul. Daewoo is even taking calls for ships that can carry 20,000 containers, double the current capacity of most megaships.

Manufacturers who ship from several continents–think consumer electronics or appliances–like the massive ships because they can lower transportation costs. One 20-foot container can hold 1,000 42″ LCD TVs. LG Electronics’ Logistics head states: “Although sea transportation is already the most energy-efficient mode of transportation, we are constantly studying…efficiencies…that save money”. Adds an industry analyst: “The trend is big ships. Its not a choice but a must. Its going to be a fight of who can carry more at lower costs”‘.

Discussion questions:

1. Why do the Koreans dominate this industry? Who are US competitors?

2. Why are megaships supply chain and OM issues?

3. Are government policies a part of this industry?