Critical Discovery

Iteration 7 DID implement the weight-splitting logic correctly, but revealed fundamental misunderstandings about the requirements.

What Iteration 7 Got RIGHT

  1. ✅ Weight-splitting logic implemented: Code correctly checks for “SUB 1LB” key
  2. ✅ Conditional sheet generation: Creates 4 sheets when split=true, single sheet when split=false
  3. ✅ Sheet naming mostly correct: Format follows ##_CARRIER_SERVICE_WEIGHT_2025 pattern

What Iteration 7 Got WRONG

Problem 1: Missing 6LB and 10LB Weight Ranges

Expected weight ranges (per split service):

  • SUB1 (< 1 lb)
  • 1LB (1-6 lbs)
  • 6LB (6-10 lbs) ← MISSING!
  • 10LB (> 10 lbs) ← MISSING!

Iteration 7 output: Only created SUB1 and 1LB sheets

Why: The source rate card file “SUB 1LB” section only has weights up to 1 lb (16 rows: 1-16 oz). When filtering by weight ranges:

  • SUB1 (< 1 lb): Gets 15 rates
  • 1LB (1-6 lbs): Gets 1 rate
  • 6LB (6-10 lbs): Gets 0 rates → Sheet not created!
  • 10LB (> 10 lbs): Gets 0 rates → Sheet not created!

Problem 2: Wrong Service Split Decision

Reference shows:

01_DHL_SMP_Ground_2025          ← Single sheet (NO split)
02_DHL_SMPP_GRO_SUB1_2025      ← Split into 4 sheets
03_DHL_SMPP_GRO_1LB_2025
04_DHL_SMPP_GRO_6LB_2025
05_DHL_SMPP_GRO_10LB_2025

Iteration 7 generated:

01_DHL_SMP_Ground_SUB1_2025    ← WRONG! Split when shouldn't
02_DHL_SMP_Ground_1LB_2025
03_DHL_SMPP_GRO_SUB1_2025      ← Correct
04_DHL_SMPP_GRO_1LB_2025

Mapping data says:

  • “DHL SM PARCEL GROUND” → service_keys: ['SUB 1LB 2025']
  • “DHL SM PARCEL PLUS GROUND” → service_keys: ['SUB 1LB 2025', 'ECONOMY 2025', 'GROUND RESIDENTIAL']

Both have “SUB 1LB” key, so according to our rule, both should split. But reference shows only “PLUS” version splits!

Problem 3: Sheet Count Mismatch

Reference: 60 total sheets (59 rate cards + 1 summary) Iteration 7: 41 total sheets (40 rate cards + 1 summary)

Gap: 19 missing sheets

Why:

  1. Missing 6LB and 10LB sheets for split services (14 services × 2 missing sheets = 28 should-be-there sheets)
  2. But we only have 19 missing total
  3. This means some services are being split that shouldn’t be (like DHL SMP Ground)

Root Cause Analysis

Issue 1: Data Source Problem

The “SUB 1LB” section in the source rate card only contains weights < 1 lb. There is NO data for 6-10 lb or >10 lb weights in that section!

This means: The agent needs to find 6LB and 10LB data from different source sections in the rate card file, not just the “SUB 1LB” section.

Looking at the source rate card structure:

  • “SUB 1LB” section → weights 1-16 oz (< 1 lb)
  • “ECONOMY” section → weights 1-70 lbs (all weights)
  • “RESIDENTIAL GROUND” section → weights 1-150 lbs (all weights)
  • “COMMERCIAL GROUND” section → weights 1-150 lbs (all weights)

Solution: When splitting, the agent needs to:

  1. Use “SUB 1LB” source for the SUB1 sheet (< 1 lb)
  2. Use “ECONOMY” or “GROUND” sources for 1LB, 6LB, 10LB sheets

Issue 2: Split Decision Logic Wrong

Current logic: IF “SUB 1LB” in service_keys → split

Actual rule (hypothesis):

  • IF service has MULTIPLE matching sources (SUB 1LB + ECONOMY + GROUND) → split into weight ranges using ALL sources
  • IF service only matches “SUB 1LB” source → single sheet with just SUB 1LB data

Test this theory:

  • “DHL SMP Ground” → keys: ['SUB 1LB 2025'] → 1 source → DON’T split ✓
  • “DHL SMPP Ground” → keys: ['SUB 1LB 2025', 'ECONOMY 2025', 'GROUND RESIDENTIAL'] → 3 sources → SPLIT ✓

This matches the reference!

Correct Rules (Revised Understanding)

Rule 1: Determine Split vs Non-Split

Split into 4 weight sheets IF:

  • Service has multiple service level keys
  • AND one of them is “SUB 1LB”

Single sheet with all weights IF:

  • Service has only one service level key
  • OR no “SUB 1LB” key

Implementation:

def should_split_by_weight(self, service_keys):
    has_sub_1lb = any("SUB 1LB" in key.upper() for key in service_keys)
    has_multiple_keys = len(service_keys) > 1
    return has_sub_1lb and has_multiple_keys

Rule 2: Source Data for Each Weight Range

When splitting, pull data from different source sections:

  • SUB1 sheet (< 1 lb): Use “SUB 1LB” source data
  • 1LB sheet (1-6 lbs): Use “ECONOMY” or “GROUND” source data
  • 6LB sheet (6-10 lbs): Use “ECONOMY” or “GROUND” source data
  • 10LB sheet (> 10 lbs): Use “ECONOMY” or “GROUND” source data

Rule 3: Always Create All 4 Sheets When Splitting

Even if some weight ranges have no data, create the sheet (it can be empty or have minimal rows).

The reference likely has placeholder data or the mapping file maps to multiple source sections.

Next Steps for Iteration 8

  1. Fix split decision: Require MULTIPLE keys including “SUB 1LB”
  2. Fix data sourcing: Use all matched service level sources, not just first match
  3. Ensure 4 sheets: Create all SUB1, 1LB, 6LB, 10LB sheets even if some ranges are sparse

Expected Impact

With these fixes:

  • “DHL SMP Ground” → Single sheet (only has SUB 1LB key)
  • “DHL SMPP Ground” → 4 sheets (has SUB 1LB + ECONOMY + GROUND keys)
  • All split services → 4 weight sheets each (14 services × 4 = 56 sheets)
  • Non-split services → Single sheets (3 sheets)
  • Total: 59 rate cards + 1 summary = 60 sheets ✓