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Hybrid home working, along with lead-time issues and product shortages has meant an increase in small order volumes, creating a host of inefficiencies within operations. The simple change of introducing a smaller sized cardboard box has resulted in a variety of quick wins.
The Problem:
A standard box size wasn’t ideal for the volume of smaller orders being shipped. A combination of back order and smaller order profiles meant that cardboard void fill was required for the larger box, resulting in customers receiving an oversized box and too much void fill to dispose of. Furthermore, the increased volume of boxes required to pass through machinery that reduces their height took time, energy and often human intervention – which have environmental and cost implications.
The Solution:
A simple solution was to source a shorter box with the same sized base, and retain the void fill method only where necessary to protect the integrity of the goods. This means that we introduced smaller boxes for smaller orders, not only reducing cardboard shipped to customers, but to reduce the amount of boxes processed by machinery within our operations - meaning less energy and potential quarantine issues.
