Packrift scenario model
Replacement And Industrial Parts: Two-pack repeat order
Dense replacement parts need a stricter damage reserve. A cheaper package can become expensive if it creates reships or warehouse exceptions. This repeat quantity band model uses 640 monthly orders and a DIM divisor of 139 to compare the current Corrugated carton against smaller protective formats.
What this scenario is testing
This version tests whether the second unit still nests efficiently or pushes the order back into carton territory. The model starts with an item profile of 9 x 7 x 4.48 in, 2.4 lb per unit, and 2 units per order. The current package is 14 x 10 x 11.5 in with 104 seconds of pack time.
Packrift treats the result as a screening recommendation. It is strong enough to prioritize a pilot, not strong enough to replace invoice analysis, damage tracking, or warehouse observation.
Candidate rule
Keep protective carton logic unless the part is bagged, capped, and proven not to puncture the package.
Assumptions used
- $0.84 per billable pound.
- $21.00 per warehouse labor hour.
- 2.35% current damage rate.
- $45.00 expected replacement or support cost.
Risk checks
- sharp edges
- grease or residue
- thread protection
- part-number readability
How to test it
- Tag orders with exactly two units.
- Record whether the second unit changes dunnage or fold behavior.
- Keep the rule separate from single-unit orders until variance is measured.
Same segment
Package Candidate Comparison
Generated from the same Packrift Flex Fit assumptions| Package | Size | Utilization | Billable weight | Cost/order | Annual impact | Status |
|---|---|---|---|---|---|---|
| Corrugated carton baseline | 14 x 10 x 11.5 in | 50% | 11.58 lb | $12.99 | $0 | Baseline |
| Multi-depth carton | 10.5 x 8.5 x 13.04 in | 69% | 8.37 lb | $9.21 | $29,092 | Best carton option for variable order depth |
| Corrugated carton | 11 x 9 x 13.79 in | 59% | 9.82 lb | $10.39 | $20,033 | General-purpose safe fit |
| Cut down current carton | 14 x 10 x 11.5 in | 50% | 11.58 lb | $12.70 | $2,246 | Operational fix using current carton family |
| Poly mailer | 11.25 x 9 x 6.39 in | 125% | 4.87 lb | $5.77 | $55,484 | does not fit modeled occupied volume, overpacked for damage risk, not recommended for this item profile |
| Padded mailer | 11.5 x 9.25 x 8.11 in | 93% | 6.21 lb | $7.13 | $45,026 | not recommended for this item profile |
| Rigid mailer | 10.5 x 8.25 x 12.54 in | 74% | 7.81 lb | $8.30 | $36,051 | DIM penalty, not recommended for this item profile |