Managing Large Order Loads to Reduce Split Shipments
Tramm
Tramm
October 9, 2024
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0 min read
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In the world of B2B commerce, having an efficient order management process is a baseline capability. Especially when large order loads are involved, the ability to achieve a high percentage of orders shipped complete drives significant transportation savings, as split shipments eat away at margins.

There are several factors that drive an increased reliance on split shipments for large order loads, sometimes acting in combination to exacerbate the issue. These include how inventory is distributed in a network, the pressure on stock levels from large orders, and the operational strain it can cause. That’s why order management precision and efficiency is at such a high premium, especially when disruptions like a major port strike throw a wrench in the works.

This article examines split shipments and the issues they cause within the supply chain and distribution and explores some best practices to avoid them. The aim is to help reduce operating expenses, improve product availability, and increase customer satisfaction.

Definition and Causes of Split Shipments

A split shipment happens when an order is divided into multiple shipments due to low stock levels, logistical constraints, or both. Often, businesses feel forced to ship what’s available immediately and send the rest later, hoping that customers can get by on the partial order in the meantime.

Some common causes of split shipments on large B2B orders include the following:

  • Multiple suppliers: Variations in supplier lead times or stock availability can cause parts of the order to arrive at different times.
  • Order complexity: Large orders often involve diverse products with different handling, storage, or shipping requirements. For instance, temperature-sensitive or hazardous goods requiring specialized transportation often lead to separate shipments.
  • Order prioritization: High-priority, in-demand products are time-sensitive, which can lead to shipping what’s on hand separately while waiting for replenishment to send the rest.
  • Warehouse fulfillment: Large orders can tax the resources of warehouse operations. SKUs stored in different locations or those requiring a different picking process can cause delays, leading to split shipments.
  • Backorders and lead time variation: Some items have significantly different supplier lead times, forcing businesses to ship only a portion of their available inventory and put the balance on backorder.
  • Inefficient systems: Without an advanced order management system (OMS), businesses lack real-time inventory visibility across multiple locations. This leads to fragmented fulfillment decisions and more split shipments.

The High Cost of Split Shipments

While some split shipments are inevitable or unavoidable due to external factors, costs go up along with higher frequency. Transportation is clearly the highest direct cost, as it’s generally the second highest expense as a percentage after labor, and more trips are required. There’s also the added complexity of scheduling additional pickups with transporters.

Speaking of labor, split shipments also hit this cost center, as they lead to more man-hours spent preparing orders through picking and packing.

Indirect costs include damage to customer relationships and reputation and the potential loss of future business. B2B customers rely on complete orders to meet production schedules or product demand. As a result, many retailers have implemented on-time in-full (OTIF) requirements. The idea is to enforce greater supply chain optimization by tight collaboration among retailers, brands, transporters, and logistics service providers.

Failure to meet OTIF requirements results in fines and penalties. A McKinsey study found that many retailers in North America are tightening OTIF requirements by narrowing delivery windows and increasing fines while revising the definition of in-full delivery.

A higher incidence of split shipments can reflect deeper issues of poor inventory management, such as stock imbalances or inefficient replenishment processes. Finally, they contribute to higher carbon emissions from the additional truck trips required.

Other Split Shipment Headaches in B2B

Split shipments introduce complexities that impact multiple areas of operations, including order tracking, invoicing, and customer communication. Each contributes to inefficiencies, often leading to higher costs, increased labor, and a decline in service quality.

Tracking Complexity

When shipments are split, tracking the order status becomes more complicated because different segments move independently through the supply chain. Logistics teams have to track each portion of the order separately, from inbound inventory to fulfillment and delivery. This involves monitoring multiple tracking numbers, the status of transporters, and estimated delivery times.

Managing Multiple Invoices

Split shipments often lead to multiple invoices, complicating accounts payable for both the shipper and customer, including reconciliation of multiple invoices against the original order. Each invoice might include different shipping costs, taxes, and fees, adding to administrative overhead. In some cases, customers might withhold payment until the entire order is delivered, adding more complexity and delaying closing the transaction.

Customer Communications

In B2B transactions, logistics and delivery impact a customer’s production schedules, inventory levels, and downstream operations. Shippers need to manage expectations around timing, coordination, and delivery schedules. Customers often rely on complete shipments to avoid production downtime, which causes frustration and the pain of adjusting internal processes.

Split shipments also require customers to coordinate with receiving teams across multiple deliveries. Additional labor and resources are needed to accept, inspect, and verify each portion of the order upon arrival.

Leveraging Technology to Optimize B2B Order Management

Advances in technology for supply chain and logistics have made it easier for businesses to optimize their inventory and order management processes in order to reduce the incidence of split shipments. Here are some examples.

WMS

A warehouse management system (WMS) provides real-time updates on inventory levels, enabling better decision-making and reducing stock-outs that lead to split shipments. Most systems can also automate inventory replenishment to ensure that items in high demand remain in stock, reducing the need for split shipments.

OMS

An order management system (OMS) integrates order data from various sources (e-commerce platform, ERP, CRM, WMS, etc.), providing visibility into inventory availability. This helps drive a higher percentage of “order complete” confirmations before shipment. An OMS also has consolidation logic for prioritizing full order fulfillment vs. partial shipments.

Tramm, a developer of a leading unified supply chain management platform, combines a powerful OMS within its transportation management system (TMS) suite. This integrated approach provides end-to-end visibility and control over order fulfillment and shipping processes. Tramm’s Order Management Module ensures that orders are fully consolidated before being released for shipment, while the TMS manages transportation in the most efficient, cost-effective manner.

Using real-time data synchronization, Tramm’s integrated approach ensures that any changes in order status, inventory levels, or shipping schedules are immediately reflected across both systems. This allows the OMS to quickly adjust fulfillment strategies if stock availability or transporter issues arise, reducing the need to rely on split shipments.

Predictive Analytics and Demand Forecasting

Predictive analytics tools tap the power of AI to enable proactive inventory management. By more accurately forecasting demand and optimizing inventory levels, both stockouts and split shipments are reduced. This technology enables users to foresee potential supply chain disruptions and adjust fulfillment strategies accordingly.

Automated Fulfillment and Transporter Routing

Fulfillment automation reduces errors in picking/packing, allowing a higher percentage of full orders to be processed and minimizing the need for split shipments.

Smart routing automatically directs orders to the most appropriate warehouse or fulfillment center, optimizing shipments and reducing transportation costs. Tramm’s Planning & Optimization Module uses advanced algorithms and visualization tools to drive better, faster load and routing decisions. The result is operational cost savings, including reduced split shipments and highly responsive planning capabilities.

Supplier Collaboration and Data Sharing

Collaborative planning includes sharing inventory and demand data with suppliers, improving stock replenishment, and reducing the likelihood of split shipments. By employing Vendor-Managed Inventory (VMI), suppliers manage stock levels, helping ensure that products are consistently available. This minimizes the need for split shipments due to out-of-stocks.

Best Practices to Minimize Split Shipments in B2B Order Management

Companies can take several steps to improve their order management processes, increase efficiency, and increase the percentage of “shipped complete” orders.

Centralized Inventory Management

Centralized inventory involves keeping all stock in one primary location, such as a warehouse, fulfillment center, or other storage facility. This central hub typically manages not only inventory but also key logistics functions like order processing and fulfillment.

In a centralized inventory system, the majority of operations, including order management and distribution, are handled from this single location, even when there are multiple sales channels or retail outlets. This strategy reduces the need for split shipments due to inventory imbalances.

Order Consolidation Policies

Order consolidation involves combining multiple orders into a single shipment. This can be done by centralizing items from multiple orders into a single location or by combining multiple orders from different sales channels into a single system.

Order consolidation can benefit businesses in several ways. This includes lower transportation costs based on economies of scale, better management of stock levels due to fewer shipments, overall simplified logistics, and a better customer experience through more complete orders.  

Smart Reordering Strategies

Smart reordering is a rules-based, automated process utilizing data analytics and AI to manage inventory levels and optimize replenishment. Unlike traditional reordering, which relies on manual tracking or fixed schedules, smart reordering uses real-time data (sales trends, demand forecasting, lead times, supplier performance, etc.) to predict when SKUs will need to be replenished.

This approach helps ensure that critical and/or high-demand products are always in stock, preventing backorders and reducing the need for split shipments.

Transparent Customer Communication

This seems like an obvious point, but too many organizations fail to keep customers updated on order status. This is especially important when unexpected drops in inventory levels or logistics snafus require a split shipment.

Always give customers the option of waiting for replenishment to send a complete order or receiving a partial shipment first. In some cases, the added expense of expedited transportation comes into play to make things right and keep to their schedule.

Continuous Monitoring and Adjustment

Regularly analyzing order data helps identify patterns that lead to increases in split shipments. By tracking trends in demand, stock levels, and fulfillment performance, you can proactively adjust inventory management, including redistributing stock across locations or improving order consolidation processes.

Leaning On Technology to Optimize Large Order Loads

Minimizing split shipments is important to maintain supply chain efficiency and reduce transportation costs. Software such as OMS, WMS, and predictive analytics tools can improve inventory management and streamline fulfillment processes. Best practices such as smart reordering, order consolidation, and continuous monitoring help reduce the incidence of split shipments.

Tramm integrates transporter management, route optimization, order management, customizable dashboards, and a control tower to optimize routing and order allocation. When shipments do need to be split, Tramm automates the process based on operational and resource requirements.

Tramm’s FleetVision Module gives users access to precise real-time data and insights. With a better understanding of fleet operations on a granular level, they can manage each load more effectively and implement performance improvement measures. The result is greater efficiency, reduced costs, and improved customer satisfaction.

To learn more about how Tramm can drive measurable improvement in your supply chain and logistics operations, request a demo today.

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