By Paul R Salmon FCILT, FSCM
In supply chains around the world, space is often treated as an infinite resource. Pallets are stacked unevenly, trucks depart half-full, and warehouses brim with air instead of product. This is not just inefficient – it’s expensive and environmentally unsustainable. It’s time we started playing Tetris with our inventory and shipments.
Just like the classic video game, the challenge is to fit pieces together in the most space-efficient way possible. But in the supply chain world, this isn’t about scoring points – it’s about saving money, improving service levels, and reducing emissions.
The Hidden Cost of Wasted Space
When space is poorly utilised, the impact reverberates across the supply chain:
Higher transportation costs: Half-filled containers and trucks mean more journeys, higher fuel consumption, and greater wear and tear. Increased carbon footprint: Logistics accounts for over 11% of global CO₂ emissions. Poor load optimisation inflates this number. Inventory holding costs: Wasted warehouse space leads to higher rents, energy costs, and less room for high-margin items.
In an era where supply chains are under pressure to be leaner, greener, and more resilient, inefficiency is no longer acceptable.
Tetris Thinking in Action
1️⃣ Container and Truck Optimisation
In commercial logistics, many companies are now using advanced load-planning software to pack trucks and containers like a game of Tetris. Algorithms consider box sizes, weights, and stacking rules to maximise every cubic metre.
Example: A major UK retailer reduced its outbound transport costs by 12% by redesigning packaging and applying 3D load optimisation. This meant fewer trucks on the road and a 15% drop in transport-related CO₂ emissions.
In defence logistics, the stakes are even higher. Every extra pallet flown to a forward operating base costs thousands in fuel and increases risk to personnel. By carefully configuring loads and using modular packaging systems, militaries can reduce the number of supply flights while maintaining readiness.
2️⃣ Warehouse Slotting and Inventory Layout
Efficient use of warehouse space is another area where Tetris-thinking applies. Poor slotting can lead to “honeycombing” – partially filled racks that waste valuable vertical and horizontal space.
Example: A leading 3PL implemented dynamic slotting based on SKU velocity and size, increasing storage density by 20% without expanding its warehouse footprint.
In the UK Ministry of Defence, volumetric data is becoming critical for optimising warehouse capacity. Instead of simply counting items, logisticians are measuring the cubic footprint of each piece of inventory to identify opportunities for tighter packing and smarter racking.
3️⃣ Packaging Redesign for Volumetric Efficiency
Sometimes the problem isn’t how you pack, but what you’re trying to pack. Oversized packaging or inconsistent box sizes makes optimisation harder.
Example: One electronics company redesigned its packaging to eliminate 30% of empty space, enabling a 25% increase in units per pallet.
Defence supply chains face similar challenges. An assessment of spares shipments for armoured vehicles revealed that custom foam inserts and standardised container sizes could increase airlift efficiency by over 15%.
The Data Behind the Game
Tetris is only possible if you know the shape of the pieces. In supply chains, this means collecting and using accurate volumetric data.
Without reliable dimensional data for SKUs, pallets, and containers, even the best algorithms can’t optimise loads. This is why modern supply chains are investing in dimensioning systems and integrating volumetric data into their ERP and WMS platforms.
In defence, volumetric data is becoming a cornerstone of supply chain resilience – enabling better forecasting, storage planning, and rapid deployment.
Why It Matters More Than Ever
The urgency to “play Tetris” with our supply chains is driven by three key factors:
✅ Rising costs: Fuel, labour, and real estate prices are increasing globally, amplifying the penalty for wasted space.
✅ Sustainability pressure: Governments and customers demand greener supply chains. Better space utilisation reduces the number of journeys and associated emissions.
✅ Geopolitical volatility: With supply chains under strain from global shocks, efficient use of transport and storage assets provides a critical buffer.
“Logistics is a finite resource. The difference between success and failure often comes down to how well we use what we have.”
From Concept to Capability
Here’s how organisations can embed Tetris-thinking:
Invest in volumetric data capture – Measure and record dimensions for all SKUs. Apply load optimisation tools – Use software to plan and simulate efficient loads. Standardise packaging and containers – Minimise variation to simplify packing. Train your people – Teach warehouse and transport teams the importance of cubic efficiency. Monitor and improve – Track space utilisation KPIs and continuously refine processes.
Conclusion: Every Cubic Metre Counts
In supply chains, space is money – and wasted space is wasted potential. By adopting a Tetris mindset, organisations can improve efficiency, reduce costs, and make a tangible contribution to sustainability.
It’s time to stop shipping air and start shipping smarter.
