If You Cannot See It, You Cannot Cut It
Most teams feel shipping is "up" without knowing whether the villain is fuel surcharges, DIM, residential fees, damages, or pack labour. A parcel packaging audit separates noise from levers you control.
description: "A repeatable monthly audit for parcel cost, damage, and pack labour — data pulls, sampling methods, and a prioritised fix list tied to packaging changes."
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Cadence
Run a light weekly pulse (damage tickets + top oversize SKUs) and a deeper monthly audit (sample orders + invoice lines).
Data to Pull
- Carrier invoice exports (or 3PL billing)
- Order lines with SKU dimensions/weights
- Pack station time studies (even a 20-order sample)
- Damage/return reasons coded
- Box inventory: which cartons actually get used
Sampling Method
Random 50 orders across channels. For each:
- Shipper used (sku of carton/mailer)
- Product cube vs box cube (void %)
- Actual weight vs billed weight
- Pack minutes
- Any protective materials
Plot void % vs damage. Plot DIM excess $ vs SKU.
Prioritised Fix List (Example Order)
- Top 10 SKUs by DIM dollars wasted → right-size (DIM guide)
- Top damage SKUs → board/fill/test (corrugate, void fill, testing)
- Slowest pack-outs → kitting or insert redesign (kitting)
- Returns pain → returns packaging
- Invoice anomalies → carrier account review (beyond packaging, but flag it)
Meeting Format (45 Minutes)
- 10 min: metrics dashboard
- 20 min: three SKU deep-dives with photos
- 10 min: decide pilots
- 5 min: owners + dates
Pilots beat slideware. Ship 30 units on the new pack; compare.
AI Assist
Use AI to cluster invoice surcharge codes or summarize damage ticket text. Do not let it invent savings percentages without your sample maths.
Audit Checklist (Print This)
For 25 random outbound orders:
Score each line: overboxed, right-sized, or underprotected. If >30% are overboxed, you have a design problem, not a packing-talent problem.
Monthly Rhythm
- Week 1: sample audit
- Week 2: change one variable (carton or fill)
- Week 3: re-sample
- Week 4: lock SOP + update pick-to-light / pack-bench cards