A method of determining pallet layers for placement by a material handling system robot can include identifying cases for inclusion in a pallet and identifying case dimension information for the cases. Using the case dimension information, the cases can be classified into at least one group, wherein each group is defined by a height range such that cases classified within a group have a height within the height range associated with that group. Cases of one of the groups can be assigned to locations within a pallet layer, wherein the pallet layer has an area within a predefined area range.