We recently worked with a manufacturer that was experiencing recurring damage to decorative wall panels during transit. Chipped edges and cracked corners were turning up on too many deliveries, and it was starting to affect customer confidence as well as costs.
The existing packaging wasn't providing enough protection, too much void space let the panels move in transit, the corners had no dedicated protection and the packing process itself was taking longer than it needed to.
We redesigned the pack around the product itself: close-fitting inserts held each panel securely in place, purpose-made corner protectors absorbed impact at the weak points, and the outer case was resized to remove the excess space that had allowed movement in the first place. We also simplified the packing sequence so operators didn't need to remember where each protective piece went.
Packing time per panel fell by 75%, from 20 minutes to just 5 minutes. As a result, a two person team increased daily output from 54 to 216 panels. Labour and facility costs also fell from £5.00 to £1.25 per panel, saving £3.75 on every panel produced. If that additional capacity were converted into sales, it could support potential annual revenue growth of around £2.9 million.
The redesign delivered benefits beyond reducing damage. It meant less time spent packing each order, fewer replacement orders to produce and dispatch, and greater confidence that products would arrive with customers in the condition they left the factory.
Contact us today to find out more information about how we can help you reduce product damage, or use our Quick Box Builder to order your custom-made boxes online!
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