The automotive manufacturer had been using different tubes to protect its fuel pumps. The operators would also twist-tie together motor accessories and attach instruction sheets to complete the pack. The entire assembly was then shrink wrapped and transported through a heat tunnel.
The packaging process was labor intensive and inconsistent from operator to operator. Additionally, the way the components were bundled made it easy for pilfering to occur. This created problems for both retailers and the manufacturer when outlets were forced to return incomplete assemblies.
Although at first glance, the new tubes were perceived as more expensive than the previous protective package solution. When the entire package process and components were considered, a different story came into view. The determination was made that it was necessary to design three different sizes, small, medium, and large, to accommodate the dozen or so fuel pumps in the line. The design had to be as compact as possible, yet offer easy loading and room for the part and accessories.
When all of the elements were factored in, the company was actually able to realize a cost savings. Contributing to that was a 25% reduction in footprint per part due to the compact nature of the design. This meant that carton and corrugated materials could be reduced, accordingly. More fuel pallets could be transported per pallet and per truck.
Additionally, more could be placed on the same amount of shelf space, for which the customer pays the retailers. This new pack assembly also excelled in time/labor studies and pack consistency.
Following successful internal testing, the customer made the switch. They were so pleased with the results that they launched a communication campaign with the automotive aftermarket trade publications, touting their “New, Innovative Packing.”
