Quite often handlings units are filled up with parts. As many parts fit inside the handlings unit will be stored inside that box. The disadvantage of that approach is, further handlings devices (i. e. forklifts) are required to transport the box to the production line or machine. Reducing packaging size means to reduce those handling activities.
Why do you must have small-sized Packaging?
Big-sized boxes require more space at the assembly line and on hand-over areas in your supply chain
Big-sized boxes separate operators inside an assembly line making it difficult to balance operators
Small-sized packaging reduces the space required at the assembly line or on hand-over areas
Small-sized packaging increases line dynamics and enables multi model lines and quick changeovers
Due to the weight and dimensions of the boxes additional handlings devices like a forklift are required
Once the box is empty the line operator has to inform the material handler as no signal is passed towards the forklift to supply new material