Reducing packing time by 43% in a logistics company
We rebuilt the packing system in a company near Wieliczka. We introduced simple feeders and changed the table layout.
The Bracia Wiśniewscy company from near Wieliczka had a problem with evening shipments. Packers couldn't keep up before the couriers arrived, which generated delays and nerves. In 9 weeks, we turned the chaos on the floor into an organized process that accelerated work by almost half.
The challenge
In March 2024, we measured that packing a standard package took an average of 4 minutes and 18 seconds. With 831 orders a day, the team of 12 had to work overtime, and still an average of 47 shipments remained for the next day. Employees walked unnecessary miles running for tape or boxes that were lying in random places.
Packing errors (wrong goods) occurred in 3.2% of cases. This generated return costs of 4,800 PLN per month. The company was losing margin, and people were tired of the constant rush that brought no results.
Our approach
We started with hard data and observations. Krzysztof Nowak spent 4 full shifts in the warehouse with a watch in hand, counting every movement of the workers' hands. We calculated that 29% of working time was empty runs and searching for tools. Facts on the table: instead of buying expensive machines, we focused on workstation reorganization.
Together with the staff, we established a new floor layout. We used 5S principles, but without unnecessary theory – simply everything had its place labeled with a marker. We tested 3 different table layouts for 5 days until we found the fastest one.
The solution
We implemented proprietary 'everything at hand' packing stations. We installed simple gravity feeders for boxes just above the worktop. Now the worker doesn't have to bend down or turn around – the box 'falls' into his hands. Knives, scanners, and poly mailers were placed on dedicated holders fixed at a 45-degree angle, eliminating errors when reaching.
We also changed the system for feeding goods for packing. We introduced a simple roller line for 2,340 PLN, which replaced manual carrying of heavy boxes from the rack to the table. The whole setup was completed with visual instructions at each station, shortening the induction of a new employee from 4 days to 6 hours.
Results
Thanks to the changes, the company not only stopped paying for overtime but also gained spare capacity for future years without increasing headcount.
Timeline
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March 2024Working time audit and mapping of 217 linear meters of the floor
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April 2024Construction and testing of a prototype packing station
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May 2024Assembly of 11 new stations and staff training
"I thought I needed a larger hall and 4 new people. It turned out that rearranging the tables and eliminating redundant steps was enough. The 43% faster result speaks for itself."