Client Type: Fast-growing startup with multiple packing areas and fulfillment teams across two U.S. locations

Overview
A rapidly expanding startup faced major operational challenges as multiple packing areas became disorganized, inconsistent, and difficult for teams to manage. With high order volume and no standardized system, both U.S. facilities struggled with cluttered workspaces, misplaced materials, and inefficient packing workflows.

Challenge
Each location had its own layout, labeling style, and material storage approach—creating confusion, slower output, and frustration among employees. Supplies were scattered, product identification was inconsistent, and staff spent too much time locating items rather than packing. Leadership needed a scalable, repeatable solution that would work across both locations.

Solution
T2P2 Solutions conducted a full workflow assessment across all packing zones and implemented a structured, repeatable system designed for clarity, speed, and long-term scalability.

Key improvements included:

• Complete reorganization of all packing areas, shelving, and material storage

• Standardized layouts and processes across both U.S. locations

• Magnetized labeling system for products on all main-floor shelves, allowing easy updates as SKUs changed

• Numerical organization of all inventory to simplify product lookup and reduce errors

• Category-based bin and shelf systems for faster item retrieval

• Streamlined material flow and workspace zones optimized for packing sequence

• Improved ergonomic design to reduce wasted movement and make daily tasks easier

Outcome
Both locations transitioned from chaotic, inconsistent environments to clean, structured, intuitive workspaces that teams could maintain with ease.

Results achieved:

• Significantly faster packing times and smoother workflows

• Immediate reduction in search time due to magnetized, numerical labeling

• Higher accuracy and fewer packing errors

• Greater team confidence and morale thanks to clear, consistent processes

• Improved scalability, allowing both locations to grow without losing efficiency

• Simplified onboarding due to standardized layouts and labeling across the U.S. operations

This project delivered a strong operational foundation that empowered the startup to scale more efficiently while making work easier, clearer, and more enjoyable for every team member.