Background: The domain of Reverse Logistics, which is lately coming more in the forefront, will serve as the focal point of this project. In the electronics industry, the importance of facilitating safe movements is constantly increasing. In order to prevent escalating the chances of damage, products have to be transported with adequate protective layers. Nevertheless, shipments with incomplete packaging are occurring, leading to damaged products arriving at the supplier side. This research aims to explore how can the packaging availability for reverse logistics be optimized in order to reduce the risk of non-repairable parts. Research Approach: The steps of the Lean approach named Define Measure Analyze Design Evaluate (DMADE) will form the backbone of the project. Literature revealed congruence on the fact that Reverse Logistics packaging is a common barrier for establishing efficient return flows. A case study at ASML is performed and the structure of the supply chain and the packaging flows are explained. Next to that, the most relevant product family is identified and the current performance of the system, in terms of packaging availability, is measured. The analysis of the current state, with the usage of 3 Lean tools (VSM-I, TIMWOODS, Ishikawa diagram), follows and based on the analysis outcomes, 9 conceptual designs are introduced in the design phase. In order to eliminate the less relevant ones, a Multi-Criteria Analysis is performed and after the requirement analysis is taken into consideration, the 2 most promising design alternatives are explained in more detail. Lastly, the evaluation phase with the mathematical model comes to assess how well each of the generated scenarios score in the decision parameter criteria. These are the Repair Success Rate, the Financial Performance and the fit with the Lean strategy. Results: After the evaluation took place, it was proved that scenario 1 results in the higher Repair Success Rate (70%), but the associated financial performance of €4,5K is barely positive. This scenario also leads to the shortest replenishment lead times of 45 days and the minimum stock levels. Scenario 3 proves to yield the highest earnings, leading to €485K, with significant tied-up capital release. As for scenario 2, the financial loss of €144K combined with the intermediate lead time and Repair Success Rate of 61% make it less attractive. Finally, scenario 4 is expected to have the highest risk of non-repairable parts (52%) and the greatest lead time of 64 days. Nevertheless, the economic gains of €267K might still place this alternative in the favorable bucket. Conclusion: The risk of supplying vendors with non-repairable parts can be truly alleviated by the installation of inspections gates and more precisely with clean bench equipment. This design will form a structural solution enabling a feedback loop towards the required stakeholders (CS Engineers, Development & Engineering) while allowing at the same time root-cause resolution of the issues found. Clean bench inspections will enable validation of the return quality and also help in addressing the quality gaps. Moreover, the supply of spare packaging materials to the customers’ cleanroom is found to have a considerable positive effect on the reverse operations. Next to that, by rolling-out such a design configuration the intense pressure within the customers’ cleanroom environment will be relieved and thus, the customer satisfaction is expected to rise. Finally, the pro-active interference for investigating the quality of the return flow yields to valuable time savings.