Excess tooling inventory and overstocked materials due to poor die/tool data

$15,000–$40,000 annually from obsolete tooling write-offs, excess storage cost, and brand reputation/regulatory risk if sustainability claims cannot be backed by data • $18,000–$45,000 annually from inflated packaging costs (supplier overhead), supply chain waste, and lost opportunity to drive sustainability with supplier • $20,000–$45,000 annually from waste write-off, storage overhead, and regulatory/brand reputation risk

Checking paper job jackets and local spreadsheets to see which dies and tooling are associated with a print form, then informally confirming with the die room if those tools exist and are available. • Checking wall charts and paper logbooks, asking senior operators, and using informal spreadsheets maintained by one or two 'go-to' people to guess what dies are on hand; if information is unclear, they request new tooling from procurement. • Co-packer estimator manually tracks die ownership (customer-owned vs. co-packer-owned) in spreadsheet; Adds margin cushion to account for uncertain tool availability; Makes phone calls to verify tool location before submitting quote