P.O.P. Display was requested to be made in Canada. Current design out of the USA. The client wanted the same display as the current one, however, it was requested that PDD Studios redesign it to "Look the same" but  use less material and reduce the cost.

The new design was made with 3 Less parts totalling 38,408 sq feet of corrugate. The Disney Display Design Reduction is 3 tons less of corrugated - the equivalent of about 21 trees.

Total cost of the display was also proportionate at 32% less than the previous year.

Re-design a carton from a tuck top ,auto bottom carton to new style to reduce packaging cost and improve line speeds.

Solution: 

A new carton design was created as a tray formed side load die cut sheet.   Additional savings noted were reduced line workers by 2, and increased stacking strength on the carton by 30%. This allowed for reduced board grades to be used.

Total annual savings will be $263,820.00

 

A separate tray former will provide open top cartons to the case packing station. The bottles will then be top loaded in and  sent to the staging section.The staging section will hold two 6 x 300 ml trays in place as a cover is attached to both cartons creating one pack.

 The packs can then be sent to the DC and separated into two 6 packs if need to fill orders. Total estimated savings = $195,000 annually

Slow production speed, difficulty finding skilled workers, high salaries, injured workers. Product is a low cost item with high packaging cost.

Solution:

Automation of a case erector, baggers and palletizer allowed for a reduction of 20 employees and increased throughput. The carton design was also reworked to accommodate the equipment.

All carton business was then awarded to one supplier and further graphic changes were made with the new capital savings.

Total estimated savings = $250,000 annually

9 different skews for one line of product. 1 insert for each skew, each piece was a different print and steel die process.

The product was attached to the insert and then placed via end load into the carton. The cartons all had 2 too 4 locking tabs.

Total time to pack was 2 min 30 sec.

Solution:

Created a one piece design with no lock tabs. Total time to attach product and pack was 45 seconds. One steel die for insert and carton combined.

 One skew, one print plate. Total estimated savings = $125,000 annually