Packaging Complexity Management Tip 15: Packaging design

Packaging Complexity Management Tip 15: Packaging design

Have you designed your packaging to maximise the opportunities to deal with complexity?


All of the different techniques we have discussed in these tips offer opportunities for dealing with low volume products and managing complexity but they may not be feasible with your existing packaging designs.  It may therefore be necessary to revisit some of the structural or artwork elements of the design to exploit specific techniques.  These can include:

  • Changing component artwork to make it standard across multiple countries (or even removing all market specific information).
  • Grouping all market specific information on certain areas of the artwork (like the EU blue box concept).
  • Providing space on components and artwork for on-line printing requirements or application of labels.
  • Reducing colours to make on-line printing easier.
  • Changing component size to provide more printing space.
  • Providing pockets or flaps on cartons for attaching leaflets and booklets.
  • Standardising sizes, platforms, layouts and templates.
  • Using colour coding, poke-yoke and pharmacodes or data matrix codes to aid control of assembly operations.

It is therefore important to ensure that a holistic approach to packaging design is taken, ensuring effective design for manufacture.

This is the fifteenth of a series of 20 blogs giving a view of methods to deal with packaging complexity. Please help me improve the thinking by adding your comments and share this with others who may have a view.

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