Many times, small issues in the way we package orders begin at a very early stage. It’s usually because no one is aware of the packaging supplies they’re using (or wasting) and/or forgetting. Taking a quick inventory will allow you to identify some of these small holes before they turn into larger issues. Below are ways to do a quick check and complete it during your normal work day.

First, watch the area where all of your packages are boxed. Take a seat at the table for 10 minutes and observe how the employees pick the boxes, tape, labels, etc. Are they searching for the correct size box? Are they picking up more tape than they need? There are many small habits that can add to the cost of each order.

Secondly, determine the first things to run out. If an employee does not have the necessary item, they cannot continue to package their orders. The worker may then pull a box that is much too large, thus adding more padding and tape to their total. One empty shelf can lead to three additional costs.

Lastly, locate those packaging supplies that are almost never moved. You may discover that there are old boxes that should be thrown away, dusty labels or bags that no longer fit your product. All of these products are taking up valuable storage space and keeping funds tied-up that could be used somewhere else. Mark the products so you don’t replace them until you’ve used up all of your existing products.

Another good idea is to count how many of the packaging supplies are damaged. Boxes can become bent if they are not properly stacked. Labels can get wet or dirty. The adhesive on tape can dry-out when it is stored near heat sources. Although it may seem minor, damage to these supplies is costing money each week.

Ask the individuals responsible for packing the orders what hinders their ability to perform their job better. They might tell you that a specific type of box is difficult to fold or that a particular type of mailer tears easily. Some solutions may come directly from their suggestions and possibly even solve some problems that were missed by just counting supplies.

Once you have completed your inventory, put the most commonly used packaging supplies next to the packing tables. Store less frequently used items farther back on shelves or in areas that require employees to search through other supplies before accessing the supplies needed. Labeling the shelves clearly will allow both you and your employees to quickly spot low stock levels and minimize unnecessary “opening” of additional containers due to confusion.

Establish a basic ordering threshold for all critical supplies. As an example; establish an order point for tape when you only have 3 cases left. Establish similar thresholds for boxes, mailers, labels, and padding. Having established an easy-to-understand ordering threshold removes uncertainty for you and your employees regarding when to order supplies, thereby reducing last-minute rush orders, which often result in higher costs and delayed arrival.

Conduct this inventory process monthly. You do not need to produce lengthy reports nor schedule meetings. A short walk around your warehouse/office, couple of counts, and 2-3 questions may be sufficient. Once you understand where your packaging supplies are going, you can reduce waste, delay shipping of orders and provide a better environment to build each order.