Avoid Being Caught Off Guard by the Next Rush

If you are having a great sales week, that is generally considered positive unless there is no tape and no boxes (or other key packaging supplies) when you go to start shipping the orders. One piece of tape and/or one empty box bin can shut down all shipments. The best time to get ready for the next big rush order is before it comes.

Use your prior years’ sales data to find out how many orders were shipped from the same time frame. Find out which items sold the most. If you cannot access past sales data, try using the last couple of busy weeks as a reference point. That will provide a general idea of how much packaging material you will likely need.

Identify your top-selling products. Ensure you have sufficient inventory of boxes, mailers, labels, tape, and padding for those products. You don’t want to count supply needs for your slower sellers in the same manner. Your faster sellers will put the most pressure on the packing station.

Plan for more orders than you anticipate you will have. If you anticipate you will ship 500 packages, then plan for 5–10 additional packages. A promotion, popular post, or large order from a customer can quickly increase your shipment volume. Having some backup inventory provides you with the flexibility to respond to an unexpected surge.

Also consider the lead time required to receive each item. Some packaging supplies will arrive tomorrow, while others may require up to a week or more to arrive. Record this information and order the slowest-arriving items first. Simply ordering your slowest supplies first can help you avoid being caught off guard when your supplier’s delivery truck shows up late.

In addition to ordering supplies, consider how much storage space you have available. Purchasing additional boxes will be ineffective if they impede your ability to move around in your facility. Store frequently used box sizes in areas where they are easily accessible. Also, store excess quantities in a clean, dry location so they won’t be damaged or lost.

Before your order volume increases, prepare your workspace. Stock your tape dispensers, test your printers, and position labels in locations where employees can easily access them. Position boxes adjacent to their corresponding products. When everything has its designated place, employees will spend less time walking, looking for supplies, and asking questions.

During peak-volume periods, create a simple daily count. Identify 5–10 of the most critical supplies and record how much was used and how much remains. This daily count should be brief; simply identify what was consumed, what still exists, and when new supplies will need to be ordered.

Once the peak-volume period concludes, review your preparation against what actually occurred. Identify which supplies became depleted and which supplies remained unused. Document these findings for future peak periods. As you continue to repeat this cycle, your counts will become increasingly accurate.

An emergency does not have to occur due to poor planning. With an advance assessment, strategic storage, and just a bit of reserve stock, your staff can maintain momentum throughout the order processing cycle. Proper planning converts packaging supplies from a last-minute concern into a reliable part of your job.