Sample CPG · Beverage & Snacks Template, audited.
30 of ~105 facilities1,145 dock doors2,998 trailer spots3 rail-served
We core-sampled 30 of ~105 plants and DCs, We mapped flagship company-owned plants and DCs spanning PBNA, Gatorade, and Quaker, biggest to smallest and most to least automated; the yard pattern held across all 30.
Network size: PepsiCo FY2017 Form 10-K, Item 2 Properties (last filing with division facility counts): ~105 North America plants (https://www.sec.gov/Archives/edgar/data/77476/000007747618000012/pepsico201710-k.htm) (FY2017 10-K)
Public audit. Not affiliated with PepsiCo. Data from satellite imagery + public records.
Modeled from a real PepsiCo network audit.
We audited PepsiCo’s yards from satellite.
Click any site for its gate, docks, and drop yards. No badge, no NDA, just what a driver sees.
PepsiCo’s stack is connected. The yards never were.
Your TMS runs the road. Your WMS runs the building. The yards are the tier between them, and they were never on the network.
Every truck gets re-keyed, re-queued, and re-found at each step. The lost time lives between the steps, which is why no single tool ever fixed it. The audit below is that gap, measured on your real yards.
A real audited site, played gate→dock→exit on the true yard geometry. Switch sites with the picker.
PepsiCo - Brookshire TX (1NA Mixing Center DC)
Driver rolls past the gate, looks for instructions on where to drop.
Movement durations are honest floors set by yard geometry; the uplift lands on the wait fields (queue + dispatch + secondary checkpoints). “Today” timings reflect the radios-and-clipboards world; “With YardFlow” reflects the protocol acting end-to-end. We may be wrong about parts of this, your actual numbers will tell us where.
What the handoffs cost across your network, and what removing them is worth
Read from satellite + Street View across all 30 facilities. At a comparable network, Primo Brands cut drop-and-hook turns from ~48 to ~24 min. Set your real volumes and margins in the calculator to put a number on it.
What surprised us reading PepsiCo’s network
Three patterns held across the sites we sampled. None of them show up on a facility list. All of them change how the yard runs.
- 01
Brookshire TX runs 120 dock doors, the most in the network, on one mixing-center roofline. Two truck gates decide whether all of them stay fed.
- 02
Only 3 of 30 audited sites are rail-served. The other 27 move everything by truck, so the yard is the only place left to win the turn.
- 03
26 of 30 sites sit behind long entry drives where the queue backs toward the road. The driverless trucks PepsiCo is adding with Gatik still wait in that line.
Turn what you saw into a number for finance
This audit is the evidence. The model is the math. Open the calculator seeded with PepsiCo’s audited yards, set your real volumes and margins, and it sizes the opportunity to the dollar.
This deep-dive is the evidence behind the /for/pepsico memo.
Are these your yards?
Tell us where we got it wrong, or see what 15 minutes of orchestration looks like on your worst site.
We are not asking for a pilot. We are asking for a conversation.
A 30-minute call, direct with Casey. We show you what we found across your yards, you tell us straight where it fits and where it does not. If the call goes well, we talk pilot. If not, you keep the analysis.
None of these times work? Email me at casey@freightroll.com or call or text me at 410-236-7434, and we’ll find one.
Casey Larkin, YardFlow. Jake, our founder, joins when it helps.
