Client: Leading Global Automotive Manufacturer
Industry: Automotive
Solution Provider: Silicon Safepack Private Limited
Focus: Reducing damages in transit through innovative packaging solutions
Background
A leading global automotive manufacturer was facing challenges with frequent damage to sensitive automotive components during transit. The company operates on a just-in-time (JIT) manufacturing system, where damaged parts not only increased costs but also led to production delays and customer dissatisfaction.
The company reached out to Silicon Safepack Private Limited, known for its expertise in industrial packaging, to find a solution that would minimize damages during transit while optimizing costs.
Challenges
- Frequent damage during long-distance transportation: Sensitive components like electronic modules, glass components, and precision-machined parts were often damaged due to vibrations, impact, and poor packaging.
- High transportation costs: Traditional packaging methods were bulky and inefficient, taking up too much space in trucks and containers.
- Environmental concerns: The manufacturer wanted to adopt eco-friendly packaging materials to align with their sustainability goals without compromising product safety.
Solution Provided by Silicon Safepack
Silicon Safepack began by conducting a comprehensive packaging audit to understand the transportation conditions, handling methods, and fragility of the parts being shipped. After a detailed analysis, they implemented the following solutions:
- Custom Packaging Design
Silicon Safepack designed a custom multi-layer packaging solution tailored to each type of component. The new design used impact-resistant cushioning materials to absorb shocks during transit. For highly sensitive parts, foam inserts were custom-molded to fit the shape of each component, reducing movement and preventing impact. - Vibration and Shock Monitoring
To monitor transit conditions, Silicon Safepack incorporated shock and vibration sensors into the packaging. These sensors provided real-time data on the forces experienced during transport, helping the manufacturer understand when and where damage was most likely to occur. - Space Optimization
The new packaging was designed to be stackable and more compact, maximizing the use of available space in trucks and containers. By improving space utilization, the manufacturer could reduce transportation costs while ensuring better protection. - Eco-Friendly Packaging Materials
To meet the client’s sustainability goals, Silicon Safepack replaced traditional plastic packaging with recyclable materials like corrugated cardboard, biodegradable foam, and water-based adhesives. This reduced the environmental impact of the packaging while maintaining its protective properties.
Results
- Reduction in Damages
After implementing the new packaging, the manufacturer saw a 40% reduction in transit-related damages. The custom cushioning and real-time monitoring helped prevent damage to delicate parts, ensuring that more products arrived in perfect condition. - Cost Savings
With the improved space optimization and reduced damage, the company experienced a 15% reduction in overall logistics costs. This was due to fewer replacements for damaged goods and more efficient use of transportation resources. - Improved Customer Satisfaction
The reduction in damaged goods led to fewer delays in production for the manufacturer, improving the overall efficiency of their supply chain. In turn, this improved their relationships with downstream partners and customers, enhancing their brand reputation. - Sustainability Impact
By switching to recyclable packaging materials, the manufacturer was able to cut down on their plastic waste by 30%, aligning with their environmental sustainability goals and contributing to a greener supply chain.
Conclusion
Silicon Safepack Private Limited successfully reduced damages in transit for the automotive manufacturer through a tailored packaging solution that combined protection, efficiency, and sustainability. The new packaging not only improved the safety of fragile components but also contributed to significant cost savings and environmental benefits. This case highlights the importance of innovative industrial packaging in maintaining product integrity during transportation and enhancing overall supply chain performance.
TATA case Study