Sizing a pool properly
Four numbers decide how many pallets you need: outbound loads per week, average days before an empty returns to you, your peak-week multiplier, and how many days of buffer you can live with. Most operations have never written these down, which is why they either run out in week three or store a thousand units they never touch.
In a one-way operation, requirement is simply consumption at peak plus buffer. In a closed loop it is governed by cycle time: pool size equals daily throughput multiplied by cycle time in days. Cutting cycle time from fourteen days to ten reduces the required pool by nearly 30% — capital released without buying anything.
