A returnable container program can result in significant logistics and material handling cost savings, but many companies that maintain their own fleets are improperly modeling the flow characteristics, then resorting to expensive high-tech solutions (like RFID) to try to resolve the shortages and loss that eventually plague so many businesses. Learn from a case study of a failed returnable container management program, and the specific techniques used to transform the program into a benchmark example. Learn some of the frequently overlooked aspects of returnable container flow, and see how these considerations can be incorporated into an algorithm to plan appropriate fleet size. Get real-life examples that illustrate the shocking disparity in fleet capacity when using standard fleet sizing practices versus a tailored algorithm specific to your company's material flow characteristics. Whether you are considering a returnable container program or in the throes of one, this presentation provides valuable insights and proven tactics to ensure success and yield the highest possible ROI. Presented at the 2019 ASCM Conference--Las Vegas, Nevada.