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The $850 Billion Returns Problem: Why Reverse Logistics Is Becoming a Margin Engine
Published
20 heures agoon
By
Retailers have spent the last decade trying to make the forward supply chain faster.
The next margin battle may be going the other way.
The National Retail Federation projected that U.S. retail returns would reach $849.9 billion in 2025. Online return rates were expected to reach 19.3%. That is no longer an edge process hiding behind the loading dock. It is an economic system large enough to influence inventory, labor, transportation, fraud, customer loyalty, working capital, and ultimately margin.
And I think the industry is still framing the problem incorrectly.
We tend to talk about reverse logistics as a transportation and warehouse problem: How do we get the item back? Where do we process it? What does the return cost?
Those questions matter. But they are not the most important question.
The critical variable in reverse logistics is time-to-disposition: how quickly can the company determine what the returned product is worth now and put it on the best economic path?
That changes reverse logistics from a cost center into a decision system.
A Returned Product Is a Depreciating Asset
Think about what happens when a $300 product comes back.
At the moment of return, the retailer does not necessarily know whether it has a $300 asset, a $240 open-box item, a $180 refurbished product, a $100 liquidation unit, a source of spare parts, or waste.
Until someone or some system makes that determination, the item is economically frozen.
It may physically sit in a store, a returns cage, a trailer, a consolidation center, or a distribution center. But economically it is stranded inventory.
And for many categories, the value of that inventory declines with time. Fashion moves. Electronics age. seasonal products miss their window. Packaging gets damaged. Inventory already in the forward network competes with the returned unit.
That is why a company can have a highly efficient transportation process and still have a bad reverse supply chain.
If it takes ten days to decide what to do with a product that could have been resold on day two, the problem was not freight. The problem was decision latency.
The Returns Network Is Not the Forward Network in Reverse
One of the most important messages coming out of NRF Rev 2026 was that reverse flows need their own strategies, metrics, partners, and operating models.
That should be obvious, but many networks still behave as though returns are simply outbound fulfillment run backward.
They are not.
A forward shipment usually has a known item, known destination, known customer, and known service commitment. A return begins with uncertainty. The product condition may be unclear. The best destination may be unknown. The disposition may depend on demand, price, repair cost, transportation cost, fraud risk, and available secondary channels.
The physical move is only one component of a much larger decision.
NRF Rev offered several good examples. IKEA has expanded buyback, resale, and spare-parts programs. Target described moving away from a one-size-fits-all reverse strategy. Best Buy has used customer data to change how open-box products are merchandised rather than treating them as a separate pile of damaged goods.
Those examples point in the same direction: the best reverse supply chains are trying to recover value, not merely process units.
The Market Gets One Thing Wrong: Cost per Return Is Not the North Star
Cost per return is useful. It is also incomplete.
Imagine two operations.
Operation A processes a return for $8 and takes twelve days to decide the disposition.
Operation B costs $11 but makes the disposition decision in twenty-four hours and recovers $35 more resale value.
Which one is better?
The answer is obvious, yet many return operations are still optimized around handling cost instead of total value recovery.
A better operating model should measure:
time from return initiation to disposition decision;
percentage of returned inventory recovered to primary sale;
recommerce or secondary-market recovery value;
markdown avoided;
days inventory remains economically unavailable;
fraud loss avoided;
transportation and handling cost by disposition path; and
customer retention after the return.
That is a very different scorecard.
Returns Are Becoming an Inventory Problem
This is where reverse logistics starts colliding with mainstream supply chain planning.
Returned inventory is not automatically available inventory. But it may become available inventory very quickly if the company can inspect, classify, and reposition it.
That means planners need some level of visibility into the return stream.
How many units are likely to come back? How many will be sellable? Where will they re-enter inventory? How long will that take? Is there demand in that location? Should the company replenish a product while hundreds of units are already on their way back?
Once returns reach the scale they have today, those questions stop being operational trivia.
They become part of inventory policy.
This is also why the traditional divide between order management, warehouse management, transportation, planning, and returns systems is getting harder to defend. The disposition decision requires information from all of them.
Fraud Makes the Decision Harder, Not Less Important
The 2025 NRF study estimated that 9% of returns were fraudulent. NRF’s 2026 discussion of return fraud also described a shift toward more organized and adaptive schemes.
The easy response is to tighten the return policy for everyone.
That can reduce fraud. It can also punish profitable customers.
The better response is to make the decision more granular.
A known customer returning a low-risk product should not necessarily face the same process as an anonymous high-risk transaction. A product with a serial-number mismatch should not follow the same flow as an unopened item returned within hours of purchase.
In other words, return policy is becoming another form of segmentation.
The company needs to determine not only what the product is worth, but also how much trust to place in the transaction.
Recommerce Changes the Economics
The growth of resale, refurbishment, repair, and recommerce makes the disposition problem more interesting.
Historically, many retailers had a limited number of paths: restock it, send it back to the vendor, liquidate it, or dispose of it.
That is changing.
Secondary markets create more possible recovery paths, but they also increase the need for better product condition data, pricing, channel selection, and inventory synchronization.
A return is no longer simply an exception to the original sale. It can become the beginning of a second commercial cycle.
That is why I would expect reverse logistics and recommerce systems to become more closely connected to pricing, order management, planning, and inventory availability over time.
The Closed Loop Is the Real Competitive Advantage
The strongest returns operation does something else that is easy to miss: it feeds information back into the forward business.
Why did the customer return the product?
Was the description wrong? Was sizing inconsistent? Was the product damaged in fulfillment? Was packaging inadequate? Did a supplier quality problem create repeat returns? Is one distribution center producing more damage than the others?
If the return reason disappears into a reverse-logistics system and never changes the forward process, the company is paying to learn the same lesson repeatedly.
The real loop should look like this:
sale → return → diagnosis → disposition → value recovery → root-cause correction.
That is not a returns process. It is a supply chain learning system.
Logistics Viewpoints has been writing about omnichannel returns management for years. What has changed is the scale and the economics.
At nearly $850 billion, returns are too large to remain a back-room workflow.
The companies that win will not necessarily be the ones with the cheapest reverse transportation. They will be the ones that make the disposition decision fastest, recover the most value, and use what came back to improve what goes out next.
That is when reverse logistics stops being a cost center and starts becoming a margin engine.
The post The $850 Billion Returns Problem: Why Reverse Logistics Is Becoming a Margin Engine appeared first on Logistics Viewpoints.
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Red Sea transits accelerate, even as Houthis advance – September 15, 2026 Update
Published
3 heures agoon
17 septembre 2026By
Weekly highlights
Ocean rates – Freightos Baltic Index
Asia-US West Coast prices (FBX01 Weekly) increased 3%.
Asia-US East Coast prices (FBX03 Weekly) increased 2%.
Asia-N. Europe prices (FBX11 Weekly) decreased 3%.
Asia-Mediterranean prices (FBX13 Weekly) decreased 12%.
Air rates – Freightos Air Index
China – N. America weekly prices increased 3%.
China – N. Europe weekly prices increased 8%.
N. Europe – N. America weekly prices increased 1%.
Analysis
The Houthis – previously in control of the elevated area miles from the Red Sea – recently seized a strategic port and island directly on the Bab el-Mandeb Strait chokepoint. This advance, together with last week’s attack on a key Saudi pipeline, marks yet another escalation in Iran-backed steps to threaten energy markets.
Some experts watching oil and bunker fuel prices climb back to May levels, see these recent developments as further evidence that strategies which reduced energy prices from initial war-time highs – mostly by drawing from reserves – are wearing thin and could now lead to an actual fuel crisis.
The Houthis had no difficulty attacking and deterring Red Sea traffic before they took control of the coastal region, but their recent gains mark a solidification of control and an escalation of the maritime threat. Nonetheless – and despite some shipper objections – container carriers continue to increase Suez Canal and southern Red Sea transits.
According to Sea Intelligence estimates, more than a quarter of Asia-Europe capacity will sail via the Red Sea in September, with 35% of Asia – Mediterranean headhaul capacity and 50% to 60% of backhauls passing through the Suez. Asia – N. Europe capacity is returning at a slower pace with 6% of headhaul and 30% of backhaul being restored so far.
War-driven higher fuel costs, and congestion at both Far East origin ports – which may keep dismal on-time rates and backlogs a factor post Golden Week and well into October – and N. Europe hubs may be changing carrier calculus for a Red Sea return. The added speed and effective capacity the new routes provide may already be responsible – together with easing, post-peak demand – for container rate decreases on these lanes.
Asia – N. Europe prices fell 3% to about $4,300/FEU last week while Asia – Mediterranean rates dropped 12% to $4,200/FEU. Daily rates on both lanes have eased to about $3,800/FEU so far this week. The sharper drop for Asia – Mediterranean prices – down $3,000/FEU from a July peak compared to $2,000/FEU for N. Europe rates – may reflect the higher rate of Red Sea capacity restoration on this lane. That, even with demand reductions and Red Sea transits, prices on these lanes remain respectively more than 20% and 50% higher than before peak season began in mid-May points to the role congestion continues to play in container rate dynamics.
Transpacific container rates meanwhile ticked up last week, remaining at peak levels as demand strength – together with Far East congestion – is keeping pressure on spot prices. The latest National Retail Federation US ocean import volume report projects October arrivals to fall 9% compared to September, with a further drop in November, suggesting that demand is already easing and should ease further soon. Port congestion – as well as blanked sailings over the holiday stretch – could nonetheless mean rates will stay quite elevated even as demand cools. While most carriers do not seem to be planning October increases, CMA CGM announced sharp PSSs especially for S. Asia – US lanes.
In air cargo, UK operations continue to recover from an air traffic control system outage that grounded thousands of flights a week ago. Overall the Freightos Air Index global benchmark is down 5% from recent, possibly typhoon-related levels, and has decreased 15% from levels hit early on in the Iran war. But rates remain 25% higher than a year ago as jet fuel costs stay high.
Far East – N. America prices climbed 3% to $6.52/kg last week and rates to Europe increased 8% to $5.25/kg. Despite global volume growth so far this year, some observers do not expect a particularly strong Q4 peak season. This stance is due partly to non-seasonal, AI-related hardware being a big driver of volumes, and limited to only some lanes – particularly, Taiwan, South Korea and S. East Asia to US corridors. On these lanes, however, some forwarders expect capacity to be tight over peak season, and even push some volumes to ocean or sea-air options.
Freightos Terminal: Real-time pricing dashboards to benchmark rates and track market trends.
Procure: Streamlined procurement and cost savings with digital rate management and automated workflows.
Rate, Book, & Manage: Real-time rate comparison, instant booking, and easy tracking at every shipment stage.
The post Red Sea transits accelerate, even as Houthis advance – September 15, 2026 Update appeared first on Freightos.
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Fed Raises Rates for First Time Since 2023, Repricing Supply-Chain Capital
Published
14 heures agoon
16 septembre 2026By
For the first time since July 2023, the Federal Reserve has raised interest rates.
The Federal Open Market Committee on Wednesday increased its target for the federal funds rate by 25 basis points to 3.75%–4.00%, reversing the easing cycle that began in 2024. The move was unanimous and reflects renewed concern that inflation remains too high despite continued economic growth.
For supply-chain leaders, the significance goes well beyond the headline rate. Higher interest rates increase the cost of financing inventory, warehouses, trucks, automation, supplier capacity and network expansion. The quarter-point move will not stop investment, but it raises the hurdle rate against which many supply-chain projects will now be judged.
The Fed is tightening into an economy that remains surprisingly resilient. Its latest projections show continued solid growth, lower unemployment than previously expected and inflation still materially above the central bank’s 2% target. Energy prices have added another layer of pressure, with higher fuel costs feeding directly into transportation, warehousing and manufacturing expenses.
That creates an uncomfortable combination for logistics operators: physical operating costs can rise at the same time that the cost of financing those operations increases.
Inventory is one of the clearest examples. Companies carrying additional safety stock to protect against disruptions must now absorb a higher working-capital cost. The question is no longer simply whether more inventory improves resilience, but whether the service and risk-reduction benefits justify the capital tied up in it.
The same pressure will apply to automation and warehouse investment. Robotics, automated storage systems and new distribution capacity can still produce strong returns, but marginal projects become harder to defend as financing costs rise. Companies are likely to scrutinize payback periods more closely and favor investments that improve utilization of existing assets before committing to major physical expansion.
Transportation markets will feel similar effects. Fleets, trailers, aircraft and other equipment are capital intensive, and higher borrowing costs increase replacement and expansion expenses. If higher rates also begin to restrain consumer and industrial demand, carriers could face more expensive capital on one side of the equation and softer freight growth on the other.
The backdrop is made more complicated by the enormous investment cycle surrounding artificial intelligence, data centers, energy infrastructure and advanced computing. Those projects continue to absorb capital, equipment and construction capacity even as the Fed attempts to cool demand elsewhere in the economy. That could produce a more uneven operating environment rather than a simple broad-based slowdown.
For supply-chain executives, Wednesday’s decision marks the return of a familiar discipline: capital must earn its way into the network.
A new distribution center must generate enough service or cost advantage. Additional inventory must provide enough resilience. Automation must produce measurable productivity. Fleet expansion must be supported by utilization. Supplier shifts must justify their transition costs.
The Fed’s move does not mean supply-chain investment stops. It means precision matters more.
The larger question now is whether Wednesday’s increase proves to be a one-time adjustment or the beginning of a renewed tightening cycle. The Fed’s latest projections suggest another increase remains possible this year.
Either way, one assumption has changed.
For much of the past two years, companies could plan around gradually cheaper capital. As of Wednesday, money is getting more expensive again.
The post Fed Raises Rates for First Time Since 2023, Repricing Supply-Chain Capital appeared first on Logistics Viewpoints.
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Why Supply Chain Exceptions Are Becoming the Real Unit of Work
Published
16 heures agoon
16 septembre 2026By
Autonomous exception management is becoming easier to define by the work it owns than by the breadth of its feature list. In 2026, the category still has a recognizable core, but the value increasingly comes from what happens around that core: how operating state is shared, how decisions are coordinated, and how quickly the system can respond when conditions change. Buyers therefore need a definition based on the work the platform is accountable for, not on the longest possible list of capabilities.
At the center, the category remains a decision-and-action capability that detects meaningful exceptions, assembles operational context, evaluates consequence, recommends or executes a response within guardrails, and monitors whether the intervention worked. Core execution discipline matters because advanced analytics or AI cannot compensate for weak transaction integrity, incomplete master data, or unreliable operating state. A modern platform has to do the foundational work consistently before its higher-order intelligence becomes valuable. This exception work is one of the operating spaces that the earlier logistics control-layer discussion was intended to address: decisions that sit between established systems of record.
That foundation now spans event detection, exception qualification, contextual data assembly, consequence assessment, prioritization, recommendation, workflow, approvals, orchestration, bounded autonomous action, auditability, and outcome feedback. The breadth matters, but breadth alone is not the differentiator. Two products can check many of the same boxes and behave very differently under real operating pressure.
The category boundary is expanding
The market is being pulled outward by growing event volume, fragmented visibility, planner overload, cross-system exceptions, shrinking intervention windows, and the gap between detecting a problem and completing the corrective action. As a result, platforms are being asked to operate on shorter planning cycles, exchange more events with adjacent systems, and support decisions that used to be handled through email, spreadsheets, meetings, or manual follow-up.
The architectural context is increasingly Visibility and execution systems produce events; an intelligence and orchestration layer determines which changes matter; decision rights and workflow determine whether software recommends, prepares, escalates, or executes; TMS, WMS, ERP, OMS, YMS, and partner systems carry out the response. That makes interoperability part of functional performance. A capability that cannot receive the required state, make a timely decision, or push a usable action into the execution environment is less valuable than its demo may suggest.
What still defines the boundary
AEM is not alerting with a new label. The category begins when technology can distinguish consequential exceptions from routine noise and materially compress the path from event to decision to action
A useful category definition should therefore separate adjacent capabilities from genuine responsibility. The question is not whether the platform can display or discuss autonomous exception management; it is whether it can reliably perform the work, govern the decisions, and sustain the operating state that the category requires.
The 2026 buyer test
Buyers should evaluate exception qualification, context depth, action connectivity, decision-rights controls, auditability, confidence handling, human escalation, cross-system orchestration, measurable latency reduction, and evidence that outcomes improve rather than simply alerts increase. The practical proof should come from operating scenarios such as a rolled ocean container, a carrier rejection, an inventory shortfall, a dock constraint, a missed milestone, a delayed inbound that threatens production, or a fulfillment promise that cannot be met as planned. Those scenarios force providers to show how the product behaves when plans change, data are incomplete, objectives conflict, or the preferred option disappears.
That is what makes the 2026 market different. The category is no longer defined only by what the software records. It is increasingly defined by how effectively it helps the operation decide and act.
Exceptions create a second operating system inside logistics
The formal process may say how transportation, warehousing, and fulfillment are supposed to run, but a large share of managerial work is triggered when reality departs from that plan. Planners gather context, compare alternatives, seek approval, communicate with partners, update systems, and then verify that the recovery worked. That exception work consumes capacity even though it is rarely modeled as a managed queue.
Treating exceptions as a unit of work changes the architecture. The system needs a way to qualify the event, assemble context, estimate consequence, assign ownership, apply decision rights, execute a response, and capture the outcome. That is why Autonomous Exception Management is more than a visibility feature: it is an operating discipline for the work created by variability.
Related Logistics Viewpoints research
2026 Autonomous Exception Management Market Map
The New Architecture of Logistics
Systems Engineering in Logistics
Your Supply Chain Isn’t Broken. Your Supply Chain Data Is.
Request the 2026 Autonomous Exception Management Market Map Brochure
The 2026 Market Map is designed to help organizations understand the structure of the AEM market, evaluate provider differences, and identify the capabilities most relevant to their operating environment. If your organization is evaluating Autonomous Exception Management capabilities or defining an exception-management strategy, I would be glad to provide the Market Map brochure and discuss the evaluation questions and provider differences most relevant to your requirements.
Request the AEM Market Map Brochure
For technology providers
Providers may request the brochure, discuss the research framework, or contact me to confirm how their capabilities are represented in the market assessment.
The post Why Supply Chain Exceptions Are Becoming the Real Unit of Work appeared first on Logistics Viewpoints.
Red Sea transits accelerate, even as Houthis advance – September 15, 2026 Update
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