Best Pallet Matching
Efficiency Without Sacrificing Accuracy
This exclusive, real-time optimization method redefines how pallet assignments are built – boosting productivity, minimizing travel, and enabling pickers to build multiple store-ready pallets at once using double or triple pallet jacks.
The result: more throughput, less labor, and zero loss in accuracy.
Key Takeaways:
- Build multiple store-ready pallets simultaneously using double or triple pallet jacks with Best Pallet Matching.
- Reduce picker travel up to 35–45% using Best Pallet Matching’s AI-powered optimization algorithms.
- Best Pallet Matching evaluates millions of pallet combinations in seconds to optimize each assignment.
- Maintain high picking accuracy across complex multi-pallet workflows with Best Pallet Matching’s voice guidance.
- Best Pallet Matching Integrates seamlessly with existing WMS platforms without operational disruption.
What if you could pick to three stores at a time and actually be more productive AND accurate than if you were just picking to one?
“Due to the diverse sizes of our stores, we were able to group orders together, utilizing the Best Pallet Matching algorithms to increase our productivity, by reducing our travel path.”
How It Works
Powered by Jennifer™, the voice, brains, and orchestration engine of the Lucas Warehouse Optimization Suite, Best Pallet Matching dynamically creates the most efficient assignments in real time.
Delivers the “Best Match”
Each worker receives the smartest combination of pallets for their equipment, reducing wasted motion and maximizing productivity.Optimizes Multi-Pallet Workflows
Assignments are built to balance efficiency, minimize travel, and increase throughput—enabling pickers to work across multiple stores on a single trip.Employs Real-Time Optimization
Advanced algorithms evaluate millions of pick combinations in seconds to build the most efficient, accurate assignments possible.Preserves and Enhances Accuracy
Unlike traditional methods, Best Pallet Matching supports multi-store picking without risking accuracy thanks to Jennifer’s voice-directed confirmations and validations.Adapts to Your Operation
Jennifer™ factors in order priority, travel distance, product attributes, restricted combinations, and more. Rules are fully configurable to your business requirements.Integrates Seamlessly
Jennifer™ connects directly with your WMS and other systems to pull order, inventory, and location data in real time.
Proven Results
15–30% travel savings
from batch optimization
5–15% additional travel reduction from optimized pick paths
5 million saved annually
Frequently Asked Questions:
Best Pallet Matching is an exclusive Lucas Systems method of real-time work creation that uses AI algorithms to determine the smartest possible grouping of pallets for double or triple pallet jack assignments. Rather than picking one store’s order at a time, the system evaluates millions of potential combinations – considering order priority, slot location overlap, travel cost, product attributes, cube compatibility, and configurable constraints – to create optimized multi-pallet units of work that allow picking for multiple stores simultaneously while maintaining accuracy.
Best Pallet Matching transforms picking efficiency by enabling workers to pick for two or three stores on a single trip through the warehouse. The system groups pallets with the greatest location overlap, dramatically reducing redundant travel between aisles. Customers have achieved 15–30% travel savings from batch optimization, an additional 5–15% from optimized pick paths, and over $5 million in annual labor cost savings, all while improving or maintaining picking accuracy through Jennifer’s voice-based validations at every pick location.
Jennifer™ evaluates millions of potential pallet combinations in real time using high-speed algorithms. It takes a “seed” pallet (the highest priority unit of work) and scores every eligible match based on slot location overlap, travel distance for the combined assignment, cube compatibility (ensuring pallets are within a configurable size difference), order priority, product attributes, and restricted combinations. The system then selects the grouping that minimizes total travel while respecting all operational constraints, thereby delivering the most efficient assignment possible at that moment.
Traditional systems use simple route-based sequencing that assigns one store’s pallet at a time and directs workers up one aisle and down the next in a fixed pattern. Best Pallet Matching fundamentally changes this by creating multi-store assignments optimized for minimal travel across all pallets simultaneously. It evaluates location overlap, cube balance, and travel cost in real time, not just route order. The result is significantly higher pick density per trip and far less wasted motion compared to conventional single-store pallet assignment.
Yes, on both counts. Travel time is reduced 15–30% through intelligent batching that maximizes location overlap, with an additional 5–15% from optimized pick paths. For product protection, the system enforces configurable constraints, ensuring pallets are matched by compatible cube and weight profiles, preventing a heavily loaded pallet from being paired with a light one that could cause instability. Jennifer also factors in product attributes and restricted combinations, so fragile or incompatible items are never grouped in ways that risk damage.
Best Pallet Matching connects seamlessly to existing systems. Jennifer™ receives orders, product data, and location information directly from the WMS through standard interfaces (RESTful APIs, flat file, or socket). The optimization runs within Lucas EthOS, requiring no WMS changes or upgrades. It applies its algorithms to available work in real time, then directs workers via voice through optimized assignments. Completed pick confirmations and productivity data flow back to the host system automatically.
Uncover the Savings You’re Leaving on the Floor
Contact us today to learn how Best Pallet Matching can help you increase throughput, reduce travel, and achieve unmatched efficiency—without sacrificing accuracy.
