For a large aluminum die-casting company supplying between 4.5 to 7 million components monthly, efficient and cost-effective packaging is crucial. With 255 different types of components requiring seaworthy packaging and strict timelines, this industry leader faced challenges in managing high costs, ensuring product safety, and avoiding penalties for mixing components. XPERTPACK stepped in with tailored packaging solutions to transform their logistics process, ensuring compliance and efficiency.
The Challenge: Complex and Costly Packaging
- Diverse Components: The number of component types surged from 8 to 255, demanding diverse packaging solutions.
- Short Timelines: New packaging designs had to be developed within a weekto meet production demands.
- Mixing Penalties: Improper segregation invited penalties during transit.
- Seaworthy Protection: Packaging required to withstand global shipping conditions.
- Overspending on Packaging: Inefficient designs led to higher costs.
XPERTPACK’s Solution
- Custom Corrugated Packaging:
- Developed lightweight triple-wall corrugated boxesto replace traditional heavy wooden crates.
- Reduced packaging weight while maintaining high stacking strength.
- Segregation and Protection:
- Created custom separators and trays to prevent mixing of components.
- Ensured optimal use of space while safeguarding against transit damage.
- Seaworthy Assurance:
- Used moisture-resistant materials to meet seaworthy standards.
- Delivered robust packaging solutions to handle global shipping challenges.
- Just-in-Time Packaging:
- Provided on-site packaging operations with 50 packers and supervisorsworking across 40 packing lines.
- Enabled 24/7 operations for zero downtime and immediate scalability.
- Comprehensive Scope:
- Introduced container Industrial lashing and securing to improve shipment stability.
- Regular BOM (Bill of Materials) maintenance and daily MIS reports to track operations effectively.
Results Delivered
- Cost Reduction: Eliminated packaging overspend by optimizing materials and processes.
- Improved Efficiency: Enabled seamless management of 4500-5000 pallets monthly.
- Increased Safety: Enhanced product protection with innovative separators and trays.
- Client Confidence: Streamlined operations with efficient packaging designs and a backward integration approach.
Conclusion
XPERTPACK’s innovative approach transformed packaging for the aluminum die-casting company. By addressing specific challenges, delivering cost-efficient solutions, and ensuring seaworthy standards, we helped them achieve operational excellence and build client confidence.
Want to explore tailored packaging solutions for your business? Contact us today!
