{"id":30821,"date":"2024-11-05T08:00:01","date_gmt":"2024-11-05T14:00:01","guid":{"rendered":"https:\/\/www.cisco-eagle.com\/blog\/?p=30821"},"modified":"2025-08-04T10:44:01","modified_gmt":"2025-08-04T15:44:01","slug":"packing-packs-a-punch","status":"publish","type":"post","link":"https:\/\/www.cisco-eagle.com\/blog\/2024\/11\/05\/packing-packs-a-punch\/","title":{"rendered":"Packing Packs a Punch"},"content":{"rendered":"<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-31318\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/10\/warehouse-packing-49661916.jpg\" alt=\"warehouse worker taping box on a conveyor line\" width=\"700\" height=\"482\" srcset=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/10\/warehouse-packing-49661916.jpg 700w, https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/10\/warehouse-packing-49661916-300x207.jpg 300w\" sizes=\"auto, (max-width: 700px) 100vw, 700px\" \/><\/p>\n<p>The moment when your customers open a box with the things they ordered is the most important part of their interaction with you. It&#8217;s your moment of truth. Well-executed packing reduces product damage, minimizes returns and leaves a positive impression. Subpar packing has the opposite effect.<\/p>\n<p><!--more--><\/p>\n<aside style=\"padding: 10px 20px 15px 25px; margin-bottom: 50px; border-radius: 15px; border: 2px solid #E4DDDD; margin: 4px 10px 4px 10px; box-shadow: 0 4px 8px 0 rgba(0, 0, 0, 0.2), 0 6px 20px 0 rgba(0, 0, 0, 0.19);\" data-type=\"summary\">\n<h4>TL;DR \u2013 Why packing stations deserve a closer look<\/h4>\n<p>Packing is one of the final steps and the last impression. The wrong box size, slow manual processes, or poor layout can quietly tank your KPIs. This post shows how to dial in your packing zone with the right data, better cartonization strategies, ergonomic improvements, and automation. Small inefficiencies add up. but so do the gains.<\/p>\n<\/aside>\n<h3>Start with the data<\/h3>\n<p>Numbers can provide a clear picture of your current packing processes. You can start with SKU data: dimensions, weights, case quantities, pick rates. Standardizing your measuring process is a good practice. When you enter dimensions for an item, do you use the dimensions as it ships, or as it\u2019s stored? Consistency will help you maintain an accurate database.<\/p>\n<p>Besides data for each SKU, you\u2019ll want to measure as much as possible pertaining to system performance. You can look at things like this:<\/p>\n<ul>\n<li>How many orders are you packing per day, or per hour? How many per associate?<\/li>\n<li>What\u2019s your carton utilization rate by percentage (on average)?<\/li>\n<li>Similarly, what\u2019s the efficiency of your shipments\u2014how much of a truckload are you using?<\/li>\n<li>How many pounds of dunnage does your packing operation generate per order?<\/li>\n<li>What is your order cycle time?<\/li>\n<\/ul>\n<p>Looking at numbers can help you determine which KPIs to target. By starting with a baseline, you can measure again after you make improvements to see how much those efforts are helping your business along.<\/p>\n<h3>Carton size<\/h3>\n<p>Evaluating carton selection for each order inevitably plays a role in packing KPIs.<\/p>\n<ul>\n<li>Too-big cartons take up more space in a shipment than strictly necessary, which means high shipping costs.<\/li>\n<li>This also creates more need for void fill materials and processes.<\/li>\n<li>Also, customers don\u2019t like to receive small items in comically large boxes.<\/li>\n<\/ul>\n<p>Carton selection affects multiple KPIs: space efficiency, corrugate used, void fill and more. Cartonization may be the area of packing where you spend the most time and attention as you look for improvements. For some systems, <a href=\"https:\/\/www.cisco-eagle.com\/category\/9818\/case-erectors\">automated case erectors<\/a> can provide significant ROI.<\/p>\n<p>This is where all that data comes in handy. The numbers can help guide you to the right mix of cartons to stock. Average order data can also show you what sizes need to be within the reach of your packers.<\/p>\n<p>Don\u2019t forget to evaluate all of this as your business changes. The ideal carton mix is never static. As your SKU mix changes and customer demand fluctuates, so will the right sizes of boxes.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-31319\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/10\/Distribution-packing.jpg\" alt=\"packing stations around a central conveyor line\" width=\"500\" height=\"344\" srcset=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/10\/Distribution-packing.jpg 500w, https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/10\/Distribution-packing-300x206.jpg 300w\" sizes=\"auto, (max-width: 500px) 100vw, 500px\" \/><\/p>\n<h3>Economizing time<\/h3>\n<p>To move your KPIs in the right direction, you\u2019ll want to make improvements in how efficiently you use cartons, but you\u2019ll also want to improve time efficiency. You\u2019re trying to get more orders out the door with no increase in damages, so making the packing process as time-efficient as possible is an obvious part of that goal. Here are a few areas to consider when it comes to saving time:<\/p>\n<ul>\n<li>Using cartons and shippers efficiently saves both space and time, because it minimizes the step of void-filling.<\/li>\n<li>Never overlook ergonomics. Besides eliminating motions that can lead to injuries, a good ergonomics program also improves production. Make sure the most frequently used supplies are within <a href=\"https:\/\/www.cisco-eagle.com\/blog\/2021\/03\/23\/a-guide-to-workstation-reach-zones\/\" target=\"_blank\" rel=\"noopener\">easy reach<\/a>, which will mean less walking, and less time, per order.<\/li>\n<li>Don\u2019t underestimate basic cleaning and organization. What\u2019s your current process for dunnage removal? We\u2019ve installed trash conveyors in the middle of pack lines for fast, continuous waste removal.<\/li>\n<li>Automation is always possible. You can automate dimensioning, for example, or incorporate automatic barcode readers. You can also automate the movement of orders between picking and packing, and between packing and shipping, using a sortation conveyor system.<\/li>\n<\/ul>\n<p><iframe loading=\"lazy\" src=\"https:\/\/www.cisco-eagle.com\/video\/frame.aspx?id=892\" width=\"640\" height=\"360\" frameborder=\"0\" scrolling=\"no\"><\/iframe><\/p>\n<h3>Small changes add up<\/h3>\n<p>Packing is a lot of small movements and decisions by your workers, and they scale up in a hurry. Manually moving corrugate waste, having to walk for certain carton size, using an excessively large box\u2014none of these things create big problems if done once. But done thousands of times over week, they take a bite out of your margins. The good news is that if you can target them through new processes, new equipment and better training, you can improve performance just as quickly.<\/p>\n<h4>More resources<\/h4>\n<ul>\n<li><a href=\"https:\/\/www.cisco-eagle.com\/blog\/2021\/04\/06\/how-to-make-packing-more-efficient\/\">How to Make Packing More Efficient<\/a><\/li>\n<li><a href=\"https:\/\/www.cisco-eagle.com\/blog\/2019\/01\/15\/order-fulfillment-is-the-first-line-of-a-great-customer-experience\/\">Order Fulfillment is the First Line of a Great Customer Experience<\/a><\/li>\n<li><a href=\"https:\/\/www.cisco-eagle.com\/blog\/2013\/12\/03\/tactics-to-reduce-small-parts-picking-errors\/\">Tactics to Reduce Small Parts Order Picking Errors<\/a><\/li>\n<\/ul>\n<div style=\"padding: 20px; border-radius: 15px; border: 2px solid #E4DDDD; margin: 4px 10px 4px 10px; box-shadow: 0 4px 8px 0 rgba(0, 0, 0, 0.2), 0 6px 20px 0 rgba(0, 0, 0, 0.19);\">\n<div class=\"row\">\n<div class=\"col-sm-4\">\n<p><a href=\"https:\/\/www.cisco-eagle.com\/uploads\/Brochures\/Order-Picking-Guide.pdf\"><img decoding=\"async\" style=\"float: right; width: 100%; max-width: 200px; height: auto; margin-left: 20px; margin-right: 18px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2024\/10\/Order-Picking-Guide-cover.jpg\" alt=\"Use the Cisco-Eagle order picking guide\" \/><\/a><\/p>\n<\/div>\n<div class=\"col-sm-8\">\n<div class=\"row\">\n<h3>Download our Order Picking Guide<\/h3>\n<p>Check out our guide for order picking methods, storage types, ergonomic considerations and inventory solutions. You will find quick, useful information on order picking and how you can maximize speed, accuracy and safety.<\/p>\n<h4><a href=\"https:\/\/www.cisco-eagle.com\/uploads\/Brochures\/Order-Picking-Guide.pdf\"><strong><em>Download the guide today<\/em><\/strong><\/a><\/h4>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Unboxing an order is the most important part of your customers&#8217; experience. How can you optimize packing zones to make sure they&#8217;re working their best?<\/p>\n","protected":false},"author":21588,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[288],"tags":[333,770],"series":[],"class_list":["post-30821","post","type-post","status-publish","format-standard","hentry","category-order-picking","tag-packaging","tag-packing"],"acf":[],"aioseo_notices":[],"publishpress_future_action":{"enabled":false,"date":"2027-04-22 02:57:48","action":"change-status","newStatus":"draft","terms":[],"taxonomy":"category","extraData":[]},"publishpress_future_workflow_manual_trigger":{"enabledWorkflows":[]},"_links":{"self":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/30821","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/users\/21588"}],"replies":[{"embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/comments?post=30821"}],"version-history":[{"count":21,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/30821\/revisions"}],"predecessor-version":[{"id":32630,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/30821\/revisions\/32630"}],"wp:attachment":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/media?parent=30821"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/categories?post=30821"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/tags?post=30821"},{"taxonomy":"series","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/series?post=30821"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}