Absolutely, Positively Operations Research: The Federal Express Story
Absolutely, Positively Operations Research: The Federal Express Story
Absolutely, Positively Operations Research: The Federal Express Story
WALTER CARLSON
DUNCAN COPELAND
tial management team, and scraped together enough funds to buy the first aircraft for his fleet: French-made Dassault
TRANSPORTATIONAIR
COMPUTERSSYSTEM DESIGN AND OPERATION
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FEDERAL EXPRESS
company discontinued air delivery service.
To maintain its customers, the company
found alternative ways to transport their
packages while it took stock of its situation.
The First Model
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lion items to over 200 countries each business day. FedEx employs more than
110,000 people worldwide and operates 500
aircraft and more than 35,000 vehicles in its
integrated system.
The first model and the planning system
that evolved around it have served as the
foundation for the $8 billion plus corporation that is the Federal Express Corporation
today. They also established corporate values for analysis and modeling that have become integral to the way FedEx does business. In the process, founder and CEO Fred
Smith has become a dedicated user and
supporter of operations research and in a
real way an active participant in it.
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FEDERAL EXPRESS
and instrument approach times. It simulated the flight of a given aircraft comprehensively from gate to gate. They used the
FLY model to calculate such factors as
flight times and engine cycles. They then
used the results to estimate crew requirements, maintenance schedules, brake component repair schedules, and other operational demands. A few months after the
first successful flight in 1973, Federal Express was renting time on an IBM 360-67
at National CSS Time Share, and Waite
wrote the original code for FLY for the 360
in PL/1.
Shortly after FLY became operational,
Brandon used the model to evaluate FedEx's expansion possibilities. Smith planned
to serve as many as 82 cities with 33 Falcons. The expansion plan, however, required additional capital. The $10 million
seed money Smith had begun with was
running out. Meanwhile, the second round
of flnancing was in jeopardy. FedEx had to
find new investors. But it had to overcome
two major hurdles to get them to sign up.
First, most potential investors had difficulty
with the hub concept. ("Do you mean that
a package sent from New York City to
Newark flies all the way to Memphis and
back?" ) Second, they wanted some proof
that they would get an adequate return on
their investments. Using FLY, Brandon constructed a model of a proposed new structure featuring 82 airports served by 33 Falcons. In a barnstorming tour. Smith, Art
Bass (who became president and chief operating officer in 1975), and others used the
82 airport model to convince investors and
employees alike that the company's basic
concept was sound and that the new system was economically attractive. With the
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21
Brandon, with the help of Bill Arthur, estimated the growth in takeoffs, landings,
and average flight length for the next flveyear period and fed this data into the models to determine fuel consumption and
costs. They added an optimistic fudge factor, just in case. J. Tucker Morse, FedEx's
internal company counsel, immediately relayed the results to Smith in Washington.
Smith's first visit was to Representative
Wilbur Mills, who, after seeing the results,
called Secretary of Energy John Sawhill.
Sawhill reviewed the computer estimates
and approved a special allocation for
FedEx, enough to keep the 82-city network
operating for several years. As it turned
out, because of the team's generous assumptions on consumption, FedEx received
a greater fuel allocation than it actually
needed during the panic.
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FEDERAL EXPRESS
over a month to do the same calculations
and to reschedule its operations.
Building the OR Team: Ponder and
Hinson
Operations research was to be central
and ongoing at FedEx. Brandon sought
help and in 1974 hired Dr. Ron Ponder of
Memphis State as a consultant. Ponder's
student, Joe Hinson, also worked as a consultant during the summer of 1974. The following August, Hinson became a full-time
employee. Ponder joined FedEx as director
of OR in 1977.
In addition to his skills in applying OR,
using GPSS tools for model building, and
his expertise in database technology.
Ponder proved to be a very capable manager. He built an OR team of 25 that became known as one of the finest OR groups
in the world. When Ponder became a senior vice-president in 1980, Hinson became
managing director of OR. He now reports
directly to Fred Smith.
Joe/Engine
The first project Joe Hinson tackled in
1974 was scheduling maintenance on the
General Electric CF-700 turbofan engines
used in the Falcons. Since the engine had
been used primarily in executive jets, it had
not logged the hours or cycles necessary to
get FAA approval for extended intervals
between maintenance sessions, a factor
known as time between overhauls (TBO).
Without a large statistical database from
which to estimate reliability, the FAA set
FedEx's TBO on the Falcons at a stringent
600 hours. Overhauls took about two to
three weeks, and since each plane flew
about six hours a day, overhauls were required every 100 days. This was a very
tight constraint for FedEx's small fleet.
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FEDERAL EXPRESS
scheduling, headed by Staunton; telecommunications, headed by Jack Cockrill; and
OR, headed by Ponder. He asked Hinson
and three other OR personnel to study the
capacity issue.
As has become the custom at FedEx,
OR was represented in the weekly senior
management meetings. During this era,
Brandon attended the meetings, often accompanied by Ponder or Hinson or some
of the other members of the OR team. This
special role was accorded the OR group because Smith, who has a degree in economics from Yale and is a liberal arts and military science buff, had learned about how
OR worked, was impressed with the results, and had come to trust the advice he
received from the OR team. The payload
problem was so hot that Smith met with
the OR group often for extensive discussions between the regular executive sessions.
The team had originally built Autoroute
as a research tool to help people understand the underlying structure of the aircraft scheduling problem. Joe Hinson beHeved that it would provide valuable
background knowledge for solving some of
the company's operations planning problems, and Brandon had encouraged him to
explore the possibilities. Now, they used
the model to determine the extent of the
impending crisis.
Autoroute is a heuristic optimizing,
scheduling model that takes loads, cities
served, and constraints, such as the latest
hour an aircraft can depart a city and the
earliest it can arrive at its destination, and
generates a complete single-hub-system
flight schedule. Over several months,
Hinson and his OR team made repeated
March-April 1997
runs of the model, making different assumptions about the composition of the
fleet, usually by substituting combinations
of two or three different types of aircraft at
a time. No matter what combinations they
used, the result was the same: FedEx could
not remain profitable unless it was allowed
to use larger planes.
Smith was troubled and moved into action. He took an apartment in Georgetown,
leaving COO Art Bass to run operations in
Memphis, and began a series of wide-ranging lobbying rounds in Washington, DC.
Virtually no one connected with airline or
air cargo regulation escaped his attention.
This effort took nearly a year. Armed with
the Autoroute results. Smith became a
strong advocate for an air cargo reform bill.
In March 1977, he testified before the senate aviation subcommittee and asked CAB
for a certificate of public convenience and
necessity. He appeared before the subcommittee again in August, testifying in support of regulatory reform. This modelbased lobbying eventually got results. In
November, the House of Representatives
passed the Air Cargo Reform Bill, and soon
thereafter President Carter signed it into
law. FedEx almost immediately filed for
permission to fly larger aircraft. It used Autoroute to evaluate the use of Boeing 727s,
among others, on FedEx's high volume
routes, and in December 1977, placed an
order for seven 727s.
Human Resource Planning
The 727s brought about new problems
with personnel planning. As FedEx expanded, introduced more hubs, and
launched a more diverse fleet, it had more
difficulty making sure its jobs and pay
scales were in order. Of special concern
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FEDERAL EXPRESS
employee performance, and in Memphis.
The prototype system, though limited in
capacity and reliability, was a vast improvement over the existing system. "For
the first time, the people in the stations
could do their own work," one executive
observed, "because they were relieved of
answering the phones and processing the
orders." Customers were also served better.
Other cities immediately demanded that
they too be added to the system. Despite
some known flaws, FedEx rolled the prototype out to 10 or 11 other cities. Ultimately
FedEx handled all customers' incoming
calls in centralized call centers, which then
sent out requests to dispatch centers located in each city FedEx served.
Given the stunning success of Project
Sydney, Smith approved a project to build
a full-scale production real-time system
eventually called Cosmosto serve the entire FedEx system. At the time, there were
many unresolved questions concerning
how many call centers to establish, where
to place them, and how to staff them.
Hinson and Ponder, with the aid of OR analyst Michael Stemad, built a customer service system model to explore the possibilities. The model clearly showed that length
of call was the most important factor in determining call-handling performance.
Queuing analysis further revealed that it
was quite easy to overload the system and
to bring it down. In fact, a sensitivity analysis applied to the model, revealed that the
length of the call was the main cost driver
for the entire system. Slight decreases in
the average length of call resulted in substantial cost savings; slight increases resulted in a substantial cost increases. Further studies suggested other methods for
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FEDERAL EXPRESS
ance for faults because it did not have the
built-in redundancy that the single hub did,
and it consumed almost all of the 12 hours
FedEx had available to process work to
meet its commitments. Hence, it did not allow much slack nor did it provide much
room for growth. Memphis remained the
single hub in the system, and in July 1979,
FedEx broke ground for the massive,
highly automated SuperHub.
Soon after the SuperHub was opened,
the model revealed additional advantages
to the concept. As a competitive move.
Smith wanted to change the committed delivery time from 12:00 noon to 10:30 am.
The model showed that the FedEx system
could deliver on that promise. Furthermore, a competitive analysis application of
the model revealed that UPS, FedEx's major competitor, could not effectively meet
this deadline. In late 1982, Tom Oliver,
head of FedEx's marketing, announced,
"We will offer 10:30 delivery, more service
options, Saturday pickups, package tracing,
and call-backs to shippers informing them
that the packages have been delivered,"
and he did this knowing that his company
could deliver on this promise and that, for
the foreseeable future, UPS could not. All
of this was consistent with Smith's strategic
emphasis on quality and reliability of
performance.
The technological infrastructure of the
company was now pretty much in place: a
mixed fleet of small planes providing service to the smaller stations and larger aircraft on the higher volume runs funneling
through a SuperHub plus centralized call
centers for answering incoming phone
calls, which were in turn dispatched to local stations for response. This infrastruc-
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As volume growth accelerated, the problem of making the stations work better and
servicing customers quicker and in a more
friendly manner surfaced. The excellent results obtained from the Project Sydney prototype and the success that the airlines had
had with computerized reservations systems suggested an approach. With this in
mind, Brandon, by now senior vice-president for planning and information systems
(including electronic data processing),
sought out and hired Howard Bedford, an
expert in airline reservation systems, to develop a comprehensive system. Bedford
hired James ToUefson, who had experience
at IBM and Avis; Henry Howell; and a
crew that soon reached about 150 people,
most of whom were also pioneers in highspeed, on-line transaction processing systems. The group was ensconced in the Advanced Systems Development Center
(ASD) located in Colorado Springs. The result was COSMOS.
COSMOS (Customer, Operations, Service, Management Operating System) is a
mainframe-based order and dispatching
system that FedEx has constantly upgraded
to cope with increasing volumes, an expanded route structure, and an ever increasing emphasis on tracking packages
from origin to final destination. Version 1
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FEDERAL EXPRESS
ations research. The existing package-handling system, young as it was, was already
coming to the end of its useful life. Nightly
package counts exceeded 50,000 and were
growing rapidly. How long would the
SuperHub concept remain optimal? What
kinds of air cargo carrying capacity would
FedEx need in the future? How fast must
planes fly to meet their tight deadlines?
Joe Hinson and his group set out to answer these questions. Using a multi-period
model of the entire FedEx system and looking five years out into the future, they first
estimated the system's carrying capacity,
the maximum amount of freight that the
system would have to carry each night.
One million pounds of total capacity appeared adequate and even provided a little
breathing room. (This seemingly conservative maximum load factor was exceeded
earlier than anticipated.) They developed
several scenarios by making different assumptions about package counts, their distribution, transportation modes (types of
aircraft and trucks), and alternative huband-spoke structures. They calculated costs
and performance factors for every activity:
the original shipper request, package
pickup, local transport, outbound station
sort, outbound line haul (air or ground),
hub sort, inbound line haul, inbound station sort, local transport, and final delivery.
Once every few weeks, Hinson would trek
across to headquarters and present his
team's preliminary results to Smith and the
executive committee. Some of the executivesalmost always Smithwould think
of some new possibilities. "What if this
were the case?" or "Couldn't we do that?"
Hinson dutifully took notes, and as each
session came to a close, he would return to
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Everything is tied to
everything else.
as much as his entire fleet of Falcons had
cost. The OR team changed its approach.
Using an updated version of Autoroute, the
team calculated the price point at which
FedEx should be indifferent between purchasing DC-lOs and another bundle of aircraft. The results rekindled Smith's interest,
and, armed with this new information, he
made an offer for four DC-10-lOCFs. The
seller initially demurred. But, because he
understood the economics of the deal very
well. Smith held tight throughout the negotiations and finally got a purchase price the
model told him he could live with. In
March 1980, FedEx christened its first
DC-10.
Another result of the butterfly explorations was even more controversial, because
it reopened old wounds from a previous
internal company battle. Various model
runs predicted that sometime during 1987
the SuperHub concept would finally reach
its practical limit. FedEx would need more
hubs. As long as the 727s could handle the
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route shows that the faster cycle time,
higher payload, longer range, and capacity
for intensive operations should make this
aircraft effective on high volume and international routes.
Meanwhile, the OR team is focusing on
the least-studied part of the total system
ground pickup and delivery in the field.
This activity accounts for about 55 to 65
percent of the total cost of packagehandling services.
An experimental courier route planning
system project is underway. FedEx is using
geo-coding and geo-positioning technology
to plot a courier's pickups and deliveries
on a map route by longitude and latitude.
One use of the map is to show the courier
the exact route she followed and to suggest
possibilities for more efficient sequencing.
Soon to follow are shortest time path estimates. These will help station managers to
plan the work of couriers under their supervision. Preliminary estimates show that
a five to 10 percent productivity improvement is possible, and almost all of it goes to
the bottom line.
Another application involves plotting
an entire station's deliveries by route
number on the station's service area map.
This will reveal operating problems in the
route structure. Since customer volumes
are always changing, and new customers
appear and old ones disappear, route balancing is a constant challenge. Turfs, as
couriers' routes are called, are currently
plotted by hand, but when the geo-coding
experiment is completed, it is likely that a
computer program can be devised to do
the task more effectively. Ultimately, the
map information may be integrated into
DADS.
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Lessons to Be Learned
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FEDERAL EXPRESS
APPENDIX: FedEx Summary of Key Events
Date
Situation
Information Source
Model
Decision or Use
March 1973
-Original idea
-Founder
-11-city schedule
(failure)
April 1973
-Emplanement
statistics
-Employment SIC
-Business
population
-Experience
-26-city system
(satisfactory)
June 1973
-Cost pressures
-Draw on the
results of the
O/D model
-Airport data
-Aircraft
characteristics
-LoadingurJoading
-Ground
operations
-Weather
experience
-FLY
-Simulation model
produces expected
flight times and
engine cycles
-Additional data
on candidate
cities
-Successful
presentation to
potential investors
-Add Los Angeles to
system early
-Need to add
financial
management to
operations
management
-Accounting data
-Financials
-Cost data
-Financial planning
model (Fin)
-Refine operations to
improve financial
performance
-OPEC rationing
imposed
-Fuel consumption
and cost
estimates
Summer 1974
-Joe/Engine model
Summer 1975
-Company growing
faster than ability
to manage well
-Expected growth
-Seasonal factors
-Actual load data
-ATA gross volume
Winter 1975
-Increased
complexity of the
system
-Load factors
-Cities served
-Arrival and
departure times
-AUTOROUTE
December
1975
-Customer calls
overload system
-Initial telephone
answering model
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35
-Prototype
centralized
system
Early 1979
-Expanded Autoroute
model
-SuperHub decision
March 1980
February 1981
Winter 1982
-10:30 AM guaranteed
delivery decision
January 1986
June 1986
-Overlay Hub
established in
Oakland, CA
Spring 1991
-Additional overlay
hubs
-Trucking justified
April 1994
Spring 1979
-More operating
problems
-System structure
-Cost of aircraft
-Facilities
characteristics
References
Sigafoos, Robert A. and Easson, Roger R. 1988,
Absolutely, Positively, Overnight! The Unofficial
Corporate History of Federal Express, St. Lukes
Press, Memphis, Tennessee.
McKenney, James L.; Copeland, Duncan C; and
Mason, Richard 0.1995, Waves of Change:
Business Evolution Through Information Technology, Harvard Business School Press, Boston,
Massachusetts.
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