In most facilities, packaging occupies a large area and many people work there for long periods of time. So, if half your packing time is spent battling with flaps and tape then the problem lies with the box design and not with the packer. Here are a few points that could be addressed at the specification stage to save a lot of time.
Choose Locking Bases Over Tuck-Ins
These types of boxes are designed to collapse down into a flat sheet and lock into shape with ease. No need to struggle with manual tuck-in bases that will fall apart under pressure.
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Get Fold Lines Scored Properly
The fold lines of the corrugated cardboard should be pre-scored so that they fall in the same place every time and create a clean, consistent crease in the board. Without proper scoring, packers will be forced to fold the board by eye, leading to inconsistency in the appearance of the completed box on the shop floor and in transit.
Cut the Number of Steps
Every additional flap, insert or piece of tape adds additional decisions that could go wrong. So, when specifying packaging for a busy production line, count the number of folds and touches required to make a single box, and seek a design that achieves the same with fewer.
Print Assembly Guides on the Board
Arrows, numbered folds or a simple illustration on the boxing can all help a packer complete a temporary job. Most suppliers (like ) would be happy to add these to your design.
Standardise Across Your Range
Different products but the same box style helps to prevent the need for staff to re-learn how to fold box(es) on a regular basis. Adopting one or two standard box designs for the majority of your products will enable staff to fold the same box style repeatedly which in turn is quicker and results in fewer errors.
Time a Trial Before You Order
Allow the packing team to build 10 mock-up boxes in the proposed new design and time them to see the real benefits of a new box design. This can also highlight potential problems to aid in the design to reduce potential repetitive strain to packing staff. The HSE states that ‘repeated movements, of an awkward posture, can be particularly hazardous’.
Getting the design right from the start will save time for years to come on every box.