Traditionally, logistics teams estimate capacity based on product volumes. For uniform pallets, this works reasonably well, but mixed pallets or varying pallet sizes complicate the calculation. IT teams often add safety margins to prevent shortages, but this approach can leave money on the table. Studies show KPIs for truck and pallet utilization are frequently overestimated by 5–10%, meaning companies pay for trucks they don’t fully need.

Advanced 3D load building software calculates exact capacity requirements by considering product dimensions, weight, stackability, compatibility, picking and loading strategies, and customer requirements (e.g., allowed pallet types and maximum heights).

By integrating Big Data analytics, logistics teams can go beyond physical constraints. Data-driven insights help answer strategic questions:

• Are current customer agreements optimized?
• Are pallets and carton dimensions used efficiently?
• Can packaging be redesigned to reduce empty space?

1. Ensure High-Quality Data
   Data accuracy is the foundation of optimization. Standardize measurements for length, width, and height across suppliers and customers. Consistently clean, validate, and update your data.
2. Measure with Effective KPIs
   Define KPIs that highlight outliers and inefficiencies. For example, calculate the “Liquified Fill Rate” of pallets—total box volume divided by pallet surface area—to assess loading efficiency.
3. Analyze Outliers
   Perform regular root-cause analyses on unusual results. Positive outliers reveal best practices, while negative outliers pinpoint areas for improvement.
4. Implement Improvements
   Address inefficiencies with process updates, staff training, packaging adjustments, or pallet changes. Repeat the measurement and analysis cycle to continuously optimize operations.

Modern logistics optimization combines the precision of 3D load planning with the predictive power of Big Data analytics. By embracing a data-driven approach, companies can minimize unnecessary costs, maximize truck and pallet utilization, and improve overall supply chain sustainability.