[CS] Packaging as part of lean logistics: how to eliminate waste in the packaging process

Inefficiencies can occur at every stage of logistics – and the packaging process is no exception. However, the Lean approach, known primarily from manufacturing, offers a great framework for optimizing packaging as well. The goal is one thing: to eliminate waste (time, motion, material) and increase value for the customer.

🔍 What is waste from a lean perspective?

The lean approach defines 7 types of waste (called muda) that can be easily transferred to packaging processes:

1. Unnecessary movement – e.g. running out for materials, shuffling or frequent turning at the table.

2. Unnecessary transport – moving goods between workplaces without adding value.

3. Waiting – for colleagues, materials, label printing, etc.

4. Overstocking – too much filler material or boxes in stock.

5. Overproduction – e.g. pre-packing of shipments that have not yet had an order confirmed.

6. Unnecessary processes – duplicate steps, e.g. repeated measurement or inspection.

7. Errors and corrections – damaged shipments, repackaging due to inappropriate package size.

✅ How to implement lean in the packaging process?

1. Standardisation of packaging

Establish clear procedures for each type of goods – what to pack, how and in what. Create simple work instructions with visual elements (photos, pictograms). Reduce error rates and training time for new workers.

2. Ergonomic packing station

Workstation layout has a major impact on productivity. All materials should be within arm’s reach, without having to walk or stretch unnecessarily. Adjustable table heights or fill dispensing systems can also help.

3. 5S for order and clarity

The 5S methodology (Seiri, Seiton, Seiso, Seiketsu, Shitsuke) leads to sustainable order:

• Sorting out the unnecessary

• Align necessary tools logically

• Clean the workplace regularly

• Standardize the layout

• Maintain habits

4. Visualization and marking

Clear identification of box sizes, fillers, labels and tools speeds up work and reduces confusion. Color-coded labels, label trays, pictograms or color-coded zones are ideal.

5. Elimination of redundant movements

Map the packaging process and identify unnecessary steps. Simple layout analyses can help – sometimes it’s enough to move the film roll closer to the table or merge two activities.

6. Measurement and improvement (Kaizen)

There is no improvement without measurement. Track wrap time, error rate or consumption of filling materials. Involve employees – they will often suggest effective changes themselves.

🎯 The result is faster and more efficient packaging

Implementing lean principles into packaging processes doesn’t mean big investments, but rather smart changes. The result is not only cost savings, but also less stress in the workplace, fewer errors and higher customer satisfaction.

At RAJA, we believe that a well-adjusted packaging process starts with simple improvements. We are happy to advise you on how to optimise your packaging workplace with the right equipment and methodology.