Cartonization Algorithm for Outbound Packaging
Developed a box-size recommendation algorithm for airfreight packaging to reduce dimensional weight charges.
Outbound warehouse operations were using oversized boxes for airfreight shipments, resulting in excessive dimensional weight charges from carriers. Manual box selection by warehouse staff was inconsistent and suboptimal.
Developed a cartonization algorithm that recommends optimal box sizes based on item dimensions, weight, and carrier-specific dimensional weight pricing rules.
The algorithm considers multiple items per shipment and minimizes total shipping cost including both actual and dimensional weight.
$2.4M in savings from reduced dimensional weight charges. The algorithm was integrated into warehouse management workflows for consistent, automated box selection.
“Sometimes the biggest savings come from the most overlooked operational details. Nobody thinks about box sizes until you show them $2.4M in waste.”