Blog post: swansont: Give Me a Pallet and I Can Move the World

Companies like Ikea have literally designed products around pallets: Its “Bang†mug, notes Colin White in his book Strategic Management, has had three redesigns, each done not for aesthetics but to ensure that more mugs would fit on a pallet (not to mention in a customer’s cupboard). After the changes, it was possible to fit 2,204 mugs on a pallet, rather than the original 864, which created a 60 percent reduction in shipping costs. There is a whole science of “pallet cube optimization,†a kind of Tetris for packaging; and an associated engineering, filled with analyses of “pallet overhang†(stacking cartons so they hang over the edge of the pallet, resulting in losses of carton strength) and efforts to reduce “pallet gaps†(too much spacing between deckboards). The “pallet loading problem,â€â€”or the question of how to fit the most boxes onto a single pallet—is a common operations research thought exercise.