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New SKU Launch Damage Prevention 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.

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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, 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 new SKU launch 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

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