Improved layout structure with complexity measures for the Manufacturer’s Pallet Loading Problem (MPLP] using a Block approach

Purpose: The purpose of this paper is to study the Manufacturers pallet-loading problem (MPLP), by loading identical small boxes onto a rectangle pallet to maximise the pallet utilization percentage while reducing the Complexity of loading.Design/methodology/approach: In this research a Block approach is proposed using a Mixed integer linear programming (MILP) model that generates layouts of an improved structure, which is very effective due to its properties in grouping boxes in a certain orientation along the X and Y axis. Also, a novel complexity index is introduced to compare the complexity for different pallet loading, which have the same pallet size but different box arrangements.Findings: The proposed algorithm has been tested against available data-sets in literature and the complexity measure and graphical layout results clearly demonstrate the superiority of the proposed approach compared with literature Manufacturers pallet-loading problem layouts.Originality/value: This study aids real life manufactures operations when less complex operations are essential to reduce the complexity of pallet loading.