Case Studies

Every Industry has its unique challenges. Here are some of the innovative ways we have helped our customers.

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Supply Chain Surgery

Our medical device client was feeling the pain of packaging bottlenecks, space constraints, and continuity of supply problems. 

Solution

  • Reformatted their warehouse
  • Remolded deliveries
  • Optimized bulk containers
  • Redesigned overpacks

Result

  • 18% - Reduction in Overpack Cost
  • 75% - Reduction in packaging Space
  • 50% - Reduction in On-hand Inventory
  • 25% - Reduction in Freight Expense

Packaging Helicopter Parts

An aerospace client wanted to lower the cost of the crates they were using to ship helicopter parts.

 

Their current crate was large and required technicians to spend a full 8-hour day taking apart the wooden crate and reassembling it once the product was placed inside. Additionally, since this crate was reusable, taking apart and putting it back together made it weaker and prone to damage.

Solution

When we got our hands on it, we redesigned the container to utilize a ramp and cart system to load the customer unit outside the crate and roll it into place.

 

We also painted the crates and utilized a plastic rain cover on the top, which reduced labor time, increased the number of times a crate could be used before damage happened. The redesigned create protected the customer’s unit better, since it could be secured at the facility, loaded on the cart with casters, and then loaded into the crate.

 

Since the redesigned crate now stays assembled the whole time, we used less robust materials and still achieved the same strength and performance, while reducing the unit cost.

Result

Reduced labor 50%

Reduced Crate price 20%

Increased # of uses for each crate > 4x

Creating Reusable Packaging

A defense contractor was having challenges with the cost of their reusable packaging and with getting the packaging back from customers.

 

The freight was costly due to their spread out supply chain, attrition rates were high, edge damage was happening, and their truck yields were not optimized due to the current design not allowing double stacking within trucks.

Solution

WIC designed a corrugated paper solution on a custom wooden pallet that was single-use and recyclable. The design was much lower in cost, and allowed double stacking in the trucks, effectively doubling the freight yield.

 

Because of the way the packaging was designed to allow for stacking, it also provided better edge protection. Finally, the design came to the customer knock down flat (KDF), which reduced their warehousing space for packaging not in use.

Result

Reduced Freight 50%

Reduced Cost 75%

Eliminated return freight Expense

Reduced Damage Rates