Manufacturing logistics professionals know waste when they see it. For decades, lean principles have guided operations with one clear goal: eliminate inefficiency. The seven classic wastes of lean—often remembered with the acronym TIMWOOD–are drilled into every leader’s mindset: transport, inventory, motion, waiting, overproduction, overprocessing, and defects. They’re hidden costs that slow production, inflate expenses, and chip away at productivity.
But wait, another waste is hiding in plain sight, one that doesn’t always show up on the factory floor. Let’s call it the 8th waste in manufacturing logistics: shipping inefficiency.
It shows up in the wrong-sized box that drives up freight charges. In the disconnected systems that force teams into manual workarounds. In the inaccurate tracking updates that frustrate customers. And unlike production waste, which is tightly managed with lean practices, this waste often slips through unnoticed.
The result? Higher costs, slower fulfillment, and weaker customer experiences.
Thankfully, just as lean principles gave manufacturers a framework to tackle the original seven wastes, modern logistics technology offers a way to eliminate the 8th.
A quick refresher on TIMWOOD
Lean manufacturing defines seven types of waste remembered by the acronym TIMWOOD:
- Transport: Unnecessary movement of materials that adds no value
- Inventory: Excess stock tying up cash and space
- Motion: Extra movement by people or machines that slows productivity
- Waiting: Idle time when resources aren’t being used efficiently
- Overproduction: Making more than what’s needed, creating surplus
- Overprocessing: Doing more work or using more resources than required
- Defects: Errors that lead to scrap, rework, or returns
Every manufacturer is trained to spot and eliminate these on the factory floor. THey’re the inefficiencies that chip away at margins and disrupt flow. They ultimately undermine customer satisfaction.
But what about the waste that happens after the product leaves the line? Shipping inefficiency, the hidden 8th waste, quietly erodes profitability while attention stays fixed on the warehouse floor.
The 8th waste: Shipping inefficiency
After the product leaves the line, shipping inefficiency causes significant waste. This hidden 8th waste quietly drains margins and customer trust. It shows up in everyday operations like these:
- Overboxing that inflates freight charges and fills trucks with wasted space
- Manual processes that slow throughput and increase the risk of costly errors
- Disconnected systems that force workarounds instead of seamless data flow
- Tracking gaps that frustrate customers and overload support teams with WISMO calls
- Carrier performance issues that delay delivery and put service levels at risk
Just like with defects or overproduction inside the plant, shipping inefficiency adds up quickly. Without the right tools it becomes an entrenched waste that repeats itself shipment after shipment.
Why it matters now
Shipping is a competitive liability in today’s manufacturing landscape. Smaller companies have tight margins, and with large scale businesses, the savings can add up to millions.
Costs are rising across the board, from freight surcharges to packaging materials. Even small inefficiencies in carrier selection or cartonization can add up to millions of dollars in wasted spend each year. What might feel like a minor shipping detail becomes a margin killer at scale.
Customer expectations are higher than ever, and late deliveries damage trust and push customers toward competitors. Whether it’s retailers waiting on apparel shipments or restaurants depending on fresh ingredients, reliability matters. A lot. And for perishable goods especially, every hour matters.
Global supply chains have grown more complex, with manufacturers needing to navigate international regulations, multiple carrier networks, and real-time visibility demands. At the same time, they have to deal with rapid growth and seasonal surges. Manual processes and outdated systems can’t keep up with that pace.
In short, this hidden 8th waste is no longer hidden. For manufacturers shipping apparel, textiles, or food and beverage products, inefficiency in logistics has become one of the most urgent threats to profitability and satisfaction.
How to eliminate shipping inefficiency
The best way to fight that 8th waste—shipping inefficiency—is the same way manufacturers fight waste on the factory floor: use the right tools. Modern logistics solutions streamline shipping just as lean principles streamline production.
This tech stack will do the job:
EasyPost Enterprise
Automate your carrier selection with EasyPost Enterprise. It helps you manage your freight, parcel, and international shipments with speed and the support our competitors can only dream of.
MagicLogic
Automate your cartonization, palletization, and load planning with MagicLogic. Our customers cut costs, reduce overboxing, improve fulfillment accuracy, and get their products delivered safely.
Advanced Tracking
Get real-time visibility, branded notifications, and automated claims with Advanced Tracking. You’ll strengthen customer trust and reduce service costs as you improve the post-purchase experience.
EasyPosts Shipping API
Connect to 100+ carriers in a single integration with EasyPost Shipping API. You’ll enjoy instant label creation, real-time rate shopping, and address validation.
In action: FabFitFun
When FabFitFun scaled its subscription box operations, shipping inefficiency threatened both costs and customer experience. By implementing EasyPost Enterprise and magicLogic, the company achieved amazing measurable results:
- Millions saved each quarter through optimized carrier selection and packaging
- 80% of overboxing eliminated
- Carton material usage reduced by 30% to 35%
Channel efficiency beyond the factory floor
Manufacturers have spent decades mastering lean principles and eliminating waste on the factory floor. Transport, inventory, motion, waiting, overproduction, overprocessing, and defects all have their place in the TIMWOOD framework. But in today’s global supply chains, a new challenge demands attention: the 8th waste of shipping inefficiency.
Left unchecked, this waste quietly erodes margins, slows fulfillment, and undermines customer trust. Tackling it requires the same commitment to efficiency, accuracy, and continuous improvement that manufacturers already bring to production.
From lean to logistics
With solutions like EasyPost Enterprise, MagicLogic, Advanced Tracking, and EasyPost Shipping API, eliminating the 8th waste is both possible and profitable. Smarter logistics deliver the measurable results of lower costs, faster fulfillment, real-time visibility, and reliability at scale.
Don’t let shipping inefficiency become your 8th waste. Lean out your logistics and protect your margins by building a shipping operation as efficient as your production line.
