The challenge:

Norfolk Southern's commitment to finding "A Better Way Forward" was put to the test when our customer and a global leader in the paper and packaging industry needed an innovative solution at their box plant.

The customer wanted to utilize the full capacity of a 60-foot high-cube boxcar to serve a facility that cannot be directly served by that equipment. For the customer, using a 60-foot boxcar would allow for almost an entire truck’s worth of additional freight per shipment. The company has height restrictions at the facility, so Norfolk Southern worked hand-in-hand with the customer to identify a solution for their infrastructure challenge.

The approach:

This project marked Norfolk Southern's first foray into a full truckload cross-docking solution.

“Historically, our focus has centered on Less-Than-Truckload services,” said Norfolk Southern Director Rail Integrated Solutions Ashley King. “However, through close collaboration and discussions with our customer, we recognized a need for additional variations of warehousing and cross-docking solutions to serve additional customer locations where rail service wasn’t the first or final mile option.”

To execute this project, Norfolk Southern brought together a Team of Teams within the Norfolk Southern organization, including the First and Final Mile Markets’ “Swiss Army knife of services:”

• Rail Integrated Solutions
• Industrial Products – Agriculture, Forests, and Consumer Products
• Triple Crown Services
• Thoroughbred Direct Intermodal Services (TDIS)
• Modalgistics
• Field Sales
• Network Planning and Operations (NPO)
• Sourcing
• Transworks
• Thoroughbred Bulk Transfer (TBT)

“This comprehensive effort showcases how Norfolk Southern and its First and Final Mile Markets team leveraged collaboration, data-driven decision-making, and effective project management to provide our customer with a tailored transportation solution that delivered for their specific needs,” said Norfolk Southern VP First & Final Mile Markets Stefan Loeb.

Each of the members of the NS team played a vital role in delivering the right transportation solution for the customer. Industrial Products Agriculture, Forests, and Consumer Goods team focused on financial analysis. Modalgistics utilized data to identify synergies that could optimize both rail and truck rates for the targeted market. Triple Crown was involved in determining dedicated truck rates between Norfolk Southern's Elizabeth, New Jersey TBT site and the customer’s delivery location. Simultaneously, efforts were made with TBT operator, RSI Logistics, the TBT team, and Field Sales to determine transload rates and assess available warehouse space.

From there, the TBT team collaborated with the customer’s subject matter experts and RSI Logistics, our Elizabeth TBT operator, to identify the necessary warehouse improvements and required equipment. Then, the team sourced contractors to upgrade the facility to meet the customer’s specifications, ensuring safe handling of freight.

Throughout, daily engagement with contractors ensured timely completion of improvements, enabling the customer to commence shipping promptly. And on August 19, the customer successfully shipped their first railcar, meeting the NS1 trip plan – a top Norfolk Southern on-time performance metric.

From there, Triple Crown and Transworks worked on automating workflows for trucking transit loads, and Triple Crown also collaborated with the customer to establish a trucking delivery appointment process.

Measurable impact:

The project isn't just a success in theory; it shows concrete results. And this initiative will introduce an additional 156 boxcars and 624 supporting trucks for final mile delivery, strengthening Norfolk Southern's position in the industry.

One of the key outcomes of this project was the successful conversion of flexible freight from dedicated truck shipments to rail. This transition delivered beyond the logistical needs of the customer. Over time, the project is anticipated to reduce the customer’s carbon emissions by 1,935 metric tons, underscoring our shared commitment to lowering the nation’s overall carbon footprint.

Smart, sustainable growth:

This project has not only solved for immediate challenges, but it also laid the foundation for future opportunities. Rail Integrated Solutions is actively working on 12 additional customer programs, leveraging the lessons learned from this project.

“Norfolk Southern, in collaboration with our customers, is redefining transportation solutions by adopting a customer-centric, operation-driven approach,” said Norfolk Southern EVP and Chief Marketing Officer Ed Elkins. “Through innovative thinking, collaboration, and a commitment to sustainability, Norfolk Southern is not only overcoming challenges, but we are also setting the stage for a more simple, reliable, efficient, and sustainable future for the transportation industry as a whole.”