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Pallet Math: How Bad Stacking Costs You Per SKU

A 6%-margin product can lose 100% of profit on a bad pallet.

A 6%-margin product can lose 100% of profit on a bad pallet.

Why this matters

Operations teams keep rediscovering the same lessons. This post lays out the patterns that actually move the needle on pallet math: how bad stacking costs you per sku.

The core idea

Throughput, not headcount, is the lever. Measure cycle time at every step and the bottleneck reveals itself.

A practical example

A 12-person prep center in Memphis cut receive-to-putaway from 4 hours to 90 minutes by changing two things — neither of them software.