Optimizing Transportation and Pallet Stability

Abstract

The research analyzes product return origins at cold and frozen food distribution warehouses by studying the effects of defective transportation and unstable pallets which result in unhappy customers and operational performance degradation. The project implemented DMAIC methodology to discover critical problem areas which encompassed temperature compliance and pallet handling methods and transportation systems. The initiative deployed IoT monitoring systems and improved pallet stability techniques to achieve projected 50% return rate reductions which led to estimated annual savings of $240,000 with a 187% ROI. The research highlights that specific process optimization strategies act as essential elements for reducing product returns while improving supply chain performance and customer satisfaction. This project demonstrates how Lean Six Sigma methods combined with innovative technologies help reach lasting operational excellence within temperature-controlled logistics operations.