Customer is a leading manufacturer of ruggedized Aircraft, Rotor Craft, and Military Electronic Parts since 1989.
Company Profile: Aerospace Parts Manufacturer
Customer is a leading manufacturer of ruggedized Aircraft, Rotor Craft, and Military Electronic Parts since 1989. Currently utilizing a corrugated die cut mailer box and separate die cut corrugated insert tray to ship 4 pieces of their product FAA-PMA Eliminator Filter. The 4 parts are packed into the mailer box and then die cut tray is placed over them inside of box for shipment via UPS/FEDEX/USPS
Packaging Challenge: Inefficient Packaging Design Causing Labor & Logistics Challenges
- The current box vendor was manufacturing box and insert tray in two separate pcs. This led to the counts of the two parts always being off and customer would need to order more of the box than the tray or vice versa.
- Having the package delivered in two parts took up more warehouse and pallet space in customer’s storage.
- Assembly of two packaging parts consumed more labor.
Having the package delivered in two parts took up more warehouse and pallet space in customer’s storage.
Analysis: Identifying the Problems with the Existing Packaging Design
Customer collaborated with Leaman Container sales professional and Design Lab Team to complete an initial review of customer’s packaging and processes. They found:
- Having box and insert separate led to difficulty when placing tray over parts packed in box.
- Tray was loose in box and did not create a tight fit.
- Tray and parts had too much movement in box when packed and closed.
- Tray was originally double wall material and was reduced to single wall material which will save paper and cost for customer.
- Having two separate parts used more material than necessary.
- Having two separate parts required two machine set ups and two manufacturing runs.
Solution: Combined Die Cut Trays and Mailer Boxes
Leaman Container combined the separate die cut tray and mailer box into one part by having the tray attached and come off the front edge of the mailer box.
Customer accepted and purchased the new solution provided by Leaman Container.
Success: Benefits & Results of the New Design
The customer accepted and purchased the new solution provided by Leaman Container. The new one-piece box is sturdier and provides more shipping protection by reducing movement in the box. The new design reduced overall corrugated material used leading to a reduction in the customer’s overall packaging spend.