Warehouse Analytics · One-page summary
Where does a beverage warehouse lose money?
Real beer and keg volumes (Montgomery County, Jun/17 to Aug/26, 27 months of data). Simulated damage and prices; ranges from 120 simulations with varying assumptions.
R$210.2K
Estimated loss per month
0.84%
Of cases moved
9/16
reason × stage combinations explain 80% of the loss
Real data · no simulation
- Cans went from 38% to 54% of the volume between 2017 and 2026; since cans break less, the raw damage rate falls on its own.
- 234 of 9,537 items (class A) make up 80% of cases moved.
- Reversals are rare (0.013% of cases), but kegs show them in 26 of 27 months.
3 findings (simulated layer)
- 46%1. of the loss comes from 3 combinations. Handling breakage at picking, pallet fall at loading and handling breakage at loading. Across simulations it ranges 43%–50%; it depends mostly on how much damage happens at picking.
- 80%2. of the cost is long neck. Glass is 51% of the volume and is damaged 2.4× as often as cans. The most robust finding: 76%–84% across every assumption range.
- +46%3. at picking, mix-adjusted. The raw rate shows +31% and makes the other stages look better, but that is just glass being replaced by cans (adjusted: −1%). The simulation plants +45%, and the method recovers it.
Each action comes from a finding and shows its estimated savings, assuming a 30% reduction.
| Picking: handling and split cases | Handling training, plastic crates for split glass cases and a review of picking pace, where the loss is growing. | R$26,964 per month |
| Long neck: pallet protection | Corner boards and extra stretch film on glass pallets, and no mixing of cans and glass when building loads. | R$50,371 per month |
| Loading and storage: standards | A load-securing standard at loading and a stacking limit marked at each location, against pallet falls and over-stacking. | R$26,874 per month on the top 3 combinations |
| Metric: mix-adjusted rate | Track damage with the packaging mix held fixed. The raw rate improves on its own when sales shift to cans and hides the worsening at picking. | A target the mix cannot fool |