that turned case hangs over the gap

We left a position out once and then nobody could agree what a finished pallet contained. Empty is fine, but your picking list needs to know about it.

Noah, yes. The internal bags sit either side of a divider and one side would cross the gap. Oscar, leaving it empty might work. I have not checked the layer above that empty position.

Check that upper layer too. I nearly suggested removing the case myself, then realised you could move the unsupported bit upwards instead of getting rid of it.

Fewer cases. Same headache if they bridge the hole.

Pavel, was your count problem labels or the people building the pallets? Ours was a screen still showing the old quantity.

Screen and dispatch sheet disagreed. Operators built what the screen said, dispatch assumed the sheet. Both groups were rather pleased with their own arithmetic.

We laid out the two layers using empty cases. Removing that position leaves a poor spot above it, as Rosa suspected. Packing has suggested straight rows with fewer cases in each layer instead.

Has anyone tried those rows with loaded cases?

Yes. Packing built the straight-row sample with our actual contents. No bottom was left spanning the old gap. They still wanted to check the completed stack, rather than judge one layer.

Good catch by packing. Are the case flaps underneath arranged the same way on every sample?

They were not on the first sample, Rosa. One case had been closed differently. We replaced it and repeated the packing check with the usual closure. That stack was accepted for this job.

What happened to the total on the dispatch sheet?

Changed with the pattern. The supervisor checked the new total against the built stack. Thanks for mentioning that early.

Less exciting pallet picture, more useful pallet. Would take that.