Ultimate Pallet Optimization Guide

Questions

What should a pallet work order include?

Deck size, cartons per layer, which carton side runs along the deck, layers, cartons per pallet, product weight, and the height and weight caps.

What is pallet optimization?

It is choosing the deck, the layer, and the height so the shipment uses fewer stable pallets without breaking the weight or height cap.

When should I leave a gap on the pallet?

When the extra carton would overhang the deck or break a this-side-up rule. Record the lower layer count.

How do I stop two shifts building different pallets?

Store one TI-HI on the SKU: layer count, orientation, layers, cartons per pallet, and the caps used.

How much unused deck is acceptable?

Whatever the grid leaves after both orientations. Do not fill it by hanging a carton past the deck.

Who is the pallet optimization guide for?

Warehouse managers, supply chain managers, 3PL operators, manufacturing managers, and operations directors who need a pallet count they can hand to a dock.

How do I compare two carton sizes?

Run each carton on the same deck and caps. Compare cartons per pallet, pallet count, and product weight.

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