The majority of innovation in intermodal transportation is aimed at improving efficiency in port terminals, inland and otherwise, according to a report from Technavio. The report also recognizes the “increasing interconnectedness” of global locations and industries of all types, which increases demands on intermodal freight transport.
That demand puts pressure on every part of the supply chain, including equipment inspection. When inspection capacity can’t keep up with freight volumes, backlogs and unplanned downtime can create inefficiencies and costs downstream.
Vahooman “Shadow” Mirkhaef, who operates Cub Terminal in McCook, Illinois, is among the leading logistics professionals talking about the operational realities behind inspection capacity and what it costs when facilities fall short.
How Inspection Capacity Impacts the Entire Supply Chain
“Equipment doesn’t take care of itself,” Mirkhaef told Tech Times. “If you don’t have the yard capacity and the M&R infrastructure to turn containers and chassis quickly, you’re pulling capacity out of the network without realizing it.”
Inspection capacity is part of that infrastructure. When a facility can’t process equipment fast enough, the impact is felt across the supply chain.
Equipment Stops Moving Because It’s Flagged or Rejected
A CIO Views article about Cub Terminal and inland supply chain opportunities points out that lagging inspection and maintenance may keep equipment moving in the short term. But equipment that’s flagged or rejected due to unresolved damage or compliance issues eventually comes to a halt, and rarely at a good time for driver or logistics companies.
Flagged or rejected equipment leads to additional costs, poor business or customer outcomes and other challenges. For shippers, it can mean delayed pickups, missed delivery windows and scrambled logistics plans. For terminals, it means managing exceptions instead of throughput.
Inspection Backlogs Slow Equipment Turn Times
Most equipment requires inspection before it’s returned to service. That process takes time, and when volumes exceed capacity, inspection backlogs increase equipment turnaround times.
The administrative side of inspections carries its own weight. For example, a 2012 FMCSA rule change eliminated the requirement for drayage drivers to file inspection reports when no defects were found on a container chassis. The FMCSA estimated that change alone would save the industry 1.636 million hours and $54 million annually, a figure that illustrates how much time routine inspection paperwork can consume across a network.
On a good day, inspections are a manageable part of terminal operations. When staffing is too low to keep up with volume, backlogs grow, tightening equipment availability across the supply chain.
Inspection and Maintenance Issues Contribute to Unplanned Downtime
When inspection capacity falls short, Mirkhaef explains, it can lead to increased risks of failure and downtime.
Deferred Maintenance Increases Risks of Failure
Most equipment failures don’t happen without warning. According to data published by Heavy Vehicle Inspection and Maintenance, 80% of failures show warning signs 30 to 90 days before the breakdown occurs. The problem is that only 27% of fleets currently use predictive maintenance tools capable of catching those signals early, leaving most operators reactive instead of proactive.
Limited Detection Capacity Lets Problems Slip Through
Manual inspection processes only work efficiently at a certain scale, and in the current intermodal system, they don’t support accuracy. The data from Heavy Vehicle Inspection and Maintenance notes that manual inspections miss 20%-30% of defects. In contrast, AI-powered systems can catch 95%-99%.
However, only 35% of facilities currently have systems capable of catching early warning signs of equipment failure.
How Shadow Mirkhaef and Other Logistics Pros Approach the Problem
Mirkhaef has consistently pointed to operational readiness at the terminal level as the foundation of network performance. Staffing, infrastructure and systems can determine whether a facility keeps equipment moving or becomes a bottleneck, especially when it comes to inspection work.
Prioritizing On-Site Maintenance and Repairs
Facilities that rely on outsourced maintenance build delays into their processes. Repairs may require equipment to leave the terminal, and that movement adds time, keeping equipment out of rotation longer.
On-site maintenance and repair infrastructure shortens those cycles, says Mirkhaef, and practices that support this approach include:
- Maintaining dedicated on-site repair bays and staffing
- Using structured maintenance schedules to reduce unplanned repair events
- Standardizing damage reporting to reduce administrative delays
- Tracking equipment condition over time and addressing issues before they cause failures
Using Predictive Maintenance Analytics and Automations
The data from Heavy Vehicle Inspection and Maintenance demonstrates that reactive maintenance doesn’t work at scale. When volumes increase, gaps in detection and response time grow too.
Technology-driven approaches, such as predictive analytics, automated gate systems and yard management platforms, help terminals stay ahead of equipment issues.
Supporting tools include:
- Predictive maintenance systems that flag equipment at the first signs of potential failure
- AI scheduling tools that optimize inspection workflows
- Real-time equipment tracking that reduces labor time in locating assets
- Automated gate and documentation systems that reduce administrative inspection burdens
Investing in Inspection Staffing and Training
Technology supports inspection capacity, but it doesn’t fully replace human experience. Terminals that are short-staffed at inspection points can create bottlenecks. In contrast, an appropriately-sized workforce that’s well-trained can move equipment through inspection faster, catch more defects on the first pass and generate less rework.
Investments that strengthen inspection capacity at the labor level include:
- Appropriate staffing ratios
- Training programs focused on defect identification
- Cross-training that ensures staff understand inspection, triage and repair functions
- Performance tracking to identify training gaps and maintain quality standards
For operators like Mirkhaef, these tips reflect daily operational disciplines that can determine whether a terminal functions as a throughput engine or a friction point.
With demand on the rise in freight, inland facilities will likely continue to see increasing volumes. Building additional inspection capacity is essential to ongoing success.
