Optimization of the logistic “fill rate” key performance indicator through the application of the DMAIC approach

Measuring and monitoring the performances of supply chains over time is a primary interest factor for companies. In this way, it is possible to determine the effectiveness and efficiency of strategies for being competitive in global markets, verify the achievement of the predetermined targets, and establish intervention and improvement measures. In this context, key performance indicators (KPIs) are widely used to measure the numerous activities performed across a supply chain. Numerous KPIs are available in the literature, and they are often customized by each user to make them more suitable for their reference context. This paper analyzes the logistic “fill rate” KPI that characterizes the shipping phase of goods by evaluating the fill rate of the transport unit used. A case study analyzes the fill rate indicator used by a multinational corporation that produces and markets food packaging. Through the DMAIC (Define, Measure, Analyze, Improve, and Control) approach, the criticalities of the current formulation of the index are highlighted, and a new model for calculating the index is proposed and applied experimentally at a plant in northern Italy.