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New SKU Launch Mailer Selection 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.

Mailer vs box decision tool Shop mailers Poly bag thickness selector

Packout checklist

  1. Pack three trial orders and record package size, finished weight, filler, closure pattern, and any visible product movement.
  2. Confirm materials: poly mailers, padded mailers, rigid mailers, return labels.
  3. Stage each mailer size in labeled slots and keep a product-fit sample beside the active pick list.
  4. For new SKU launch work, treat mailer selection 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

Stage each mailer size in labeled slots and keep a product-fit sample beside the active pick list.