All Member Forum

My unit loads are arriving at my customer's dock no longer wrapped to the pallet.  Furthermore, the pallets look like they are near end of life.  My unsupported suspicion is that there has been some unauthorize pallets swaps taking place in transit.  Is this a real thing that happens?  If so, how do I prevent it?

I guess that's possible, but I've never heard of it happening and it's a lot of effort to swap out something that honestly isn't all that expensive. It's entirely possible that the stretch wrap is slipping and that the transit is rough, so the pallets are taking significant damage, but I don't know anything about your product/pallet config, so I can't tell you if that's realistic in your case. 

If you really think pallets might be getting swapped out, run a test to find out. If you coordinate with your customer to have them returned or if you could meet the shipment there yourself, you could place a datalogger/pallet GPS on some of your pallets and see if they arrive at the dock. Or you could have some markings placed on the underside of the pallets that could be looked for at the customer's warehouse. Placing the markings underneath the stringers would make it less obvious that a pallet has been marked. 

------------------------------
Stanley Goldstein
Senior Packaging Engineer
Prestige Consumer Healthcare
------------------------------

In the auto industry, there is a frequent occurrence where pallets and/or top caps as well as bins and totes are returned to the wrong location.  Frankly, any 'standard size' packaging is susceptible.  In most cases I do not believe it to be nefarious.  But rather a byproduct of a large scale logistics operation managed by an OEM or third party.  Especially when cross docks are involved, or when multiple suppliers' packaging is being returned on the same truck, there are occurrences where things are not returned to the correct origin.  This was so common that the OEMs I've worked with only label their pallets and top caps with their own markings - not that of a supplier.

While it is (hopefully) the correct size and quantity returned, the packaging quite often has labels from a different supplier.  Which brings me to the only suggestion I can think of to try to prevent or discourage this from happening.  You may consider adding some type of permanent label or placard or stamp to your pallets or other packaging - IF allowable.  With returnable / reusable packaging, there is often a 'hot stamp' or 'placard' that can be added.  With wood pallets you may consider a stencil/paint or a 'brand' style of identification stamp.  This may help to visually identify your packaging as 'your' packaging.

Aside from that, your best bet is likely to 'communicate' with your customer or shipping partner.  If this is a new occurrence, perhaps it can be corrected.  If it is a regular occurrence for them, then you have some understanding and can manage expectations accordingly.  Finally, if it is intentional / theft, it may be difficult to prove or to be compensated - but with proper documentation and communication you may be able to go through some type of reimbursement or replacement process with either the customer or shipper.

But for what it's worth, I remember my first visit to a large OEM assembly plant.  I was surprised - and a little relieved - to see standard sized packaging (pallets, top caps, bins totes, etc.) from MANY different OEMs sitting in their packaging consolidation area.  And every supplier there described that they routinely receive standard packaging that belongs to other suppliers/OEMs.  It let me know that it wasn't just me or my location that was experience this.

Good luck!

------------------------------
Joseph Beaudry CPP
Director, Supply Chain Management
Stellantis
Rochester Hills MI
(586) 354-0428
------------------------------