When packing volume grows, the instinct is to hire more staff. But before adding headcount, it's worth asking: is the current team working at full efficiency? In most operations, the answer is no — and the gap between current performance and maximum efficiency is filled with preventable friction. Here's how to close that gap without adding a single person.
Improvement #1: Eliminate Supply Search Time
Every time a packer leaves the station to find tape, a box, or a label, you lose 30-60 seconds. Multiply that by dozens of orders per shift and the total is significant. Use stackable clear storage bins with lids to keep every supply type in a dedicated, labeled location at the station. Clear bins mean packers see supply levels without opening anything — and restock before running out rather than after.
Improvement #2: Switch to a Tape Gun at Every Station
Hand-tearing tape is the single biggest speed killer at the packing station. The Tape King tape dispenser gun with bonus tape roll cuts cleanly in one motion and applies tape consistently every time. For multi-station operations, the 2-pack tape dispenser gun set equips two stations at once. Pair with the 24-roll 3-inch premium packing tape so stations never run dry mid-shift.
Improvement #3: Pre-Sort Boxes by Size
Choosing the right box size shouldn't require thought or measurement. Stock the 32-pack assorted size shipping boxes and store each size in a dedicated, labeled location. Packers grab the right size by location — no comparing, no hesitation, no wasted motion.
Improvement #4: Standardize the Packing Sequence
Inconsistent packing sequences create inconsistent times. Define a standard sequence — verify SKU, select box, add product, add filler if needed, apply label, seal with H-tape pattern — and train every packer to follow it in the same order every time. Consistency is faster than improvisation because it becomes automatic.
Improvement #5: Reduce Station Restocking Interruptions
Packers who stop to restock their own stations lose momentum. Use 6-pack 20-quart stackable bins for bulk supply storage near (but separate from) the packing station. Assign restocking to a dedicated role or schedule it at shift transitions — never during active packing.
The Result: More Output, Same Team
Implementing these five improvements typically increases packing throughput by 20-40% without adding staff. Measure your current orders-per-hour before and after each change so you can quantify the improvement and identify which changes had the most impact in your specific operation.