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High-Return SKU Damage Prevention Playbook

Use this when one SKU appears repeatedly in return/damage notes. This playbook is for teams trying to reduce returns tied to packaging condition.

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Packout checklist

  1. Review the last ten return notes and group them into damage, fit, label, seal, or carrier-handling causes.
  2. Confirm materials: corrugated boxes, protective wrap, edge protection, void fill.
  3. Keep a pass/fail packed sample at the bench and require a supervisor check for new fragile SKUs.
  4. For high-return SKU work, treat damage prevention 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

  • Update the outbound packout rule.
  • Add a returns inspection code.
  • Recheck the SKU after the next shipment batch.

Station setup

Keep a pass/fail packed sample at the bench and require a supervisor check for new fragile SKUs.