The manufacturer was shipping plastic materials on extra-wide pallets that customers could not fit into their storage racks. Millwood recommended adding a 2' x 4' section to the back of the pallets, making them the same width. This small design change solved the customer storage issue while only increasing pallet costs by 1.5% and without changing shipping.

1. Redesign Meets Performance Criteria
Situation
• A manufacturer that shipped long, flexible plastic materials on 8’, 10’ and 12’ wide pallets.
The extra-wide pallets worked for shipping; however, the manufacturer’s customers couldn’t
load the pallets into their racks. The manufacturer wanted an alternative pallet that could solve
the problem without increasing its costs.
Solution
• Using the Pallet Design System software, Millwood recommended the addition of a 2’ x 4’
the same width as the pallet across the back. The design change added just 1.5% to the cost
of the pallet and allowed customers to store the product in a rack system.
Results
• No change in shipping.
• Customer storage issue solved!
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