TOPS Pallet Pattern Documentation & SOP

Cost Optimization, Foundational Process, & Packaging Optimization

Client Needs

Document plant pallet patterns in TOPS (previously undocumented, causing customer fines e.g. Walmart overhang); create a TOPS SOP and identify cost savings.

The Challenge

Highly customized TOPS reporting; requested primary-package visuals doubled the work; items produced at different plants with different packaging sizes.

Our Approach

  • Visited 6 plants documenting 68 pallets by measuring/weighing cases
  • Worked with TOPS to model a gallon milk jug
  •  Photographed pallets/cases; built customized reporting

The Impact

  • 68 pallet patterns reviewed across 6 plants
  • 66 patterns developed 
  • Identified 6 items produced in multiple facilities with differing packaging and 4 items that could increase pallet count 
  • Delivered a TOPS SOP

Let’s Talk Efficiency Gains

Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.

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