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New SKU Launch Cartonization Playbook

Use this when a product has no approved package spec yet. This playbook is for operations managers introducing a new product into the pack flow.

Box size calculator DIM weight calculator Boxes and mailers

Packout checklist

  1. Pack three trial orders and record package size, finished weight, filler, closure pattern, and any visible product movement.
  2. Confirm materials: corrugated boxes, void fill, carton sealing tape, packing slips.
  3. Keep three right-size carton families, filler within arm's reach, a scale, and a sample packed order at the bench.
  4. For new SKU launch work, treat cartonization as a controlled operation: define the package spec, stage the right materials, and inspect the first completed orders before volume scales.
  5. Record the approved package size, finished weight, label position, and exception rule.

QA checks

  • Approve one primary package and one fallback size.
  • Photograph the accepted packout.
  • Add the package spec to the pick/pack note before the first live batch.

Station setup

Keep three right-size carton families, filler within arm's reach, a scale, and a sample packed order at the bench.