Optimize Global Shipments with Customized Dunnage Solutions

Report
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Optimize Global
Shipments with
Customized Dunnage
Solutions
Scott Krebs and Jenny Orszula
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|
www.orbiscorporation.com
Global Dunnage and
Packaging Solutions
• Value of reusable dunnage for
the global automotive industry
• Current automotive packaging trends and
the impact that dunnage has on each:
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Shipping new materials
International supply loops
Managing transportation costs
Standardization
Shift to small lot
• Review of common materials and
applications
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Review of Shipping Forms of
Reusable Packaging
Bulk Containers
Unit loads of pallets,
totes and top caps
Custom Protective
Dunnage
Steel Racks
Today’s focus is protective dunnage.
Collapsible Totes
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Why Reusables and Dunnage for
the Global Automotive Industry?
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•
•
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Better part protection
Improved pack density
Reduced waste
Better part presentation
Standardized work flow/line side
Optimized transportation
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Current Global Packaging Trends
•
•
•
•
•
New Materials Being Shipped
International Supply Loops
Managing Transportation Costs
Standardization
Shift to Small Lot
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Packaging Trend #1
• Shipping New Materials: Challenges of handling and protecting the
new materials being used in vehicles to reduce the total vehicle
weight and increase MPG
– Aluminum replacing steel
– New light weight resins for plastic parts
• Dunnage Impact: Through testing, new dunnage materials have
been developed that outperform the traditional dunnage materials
when used to protect the new lightweight automotive parts.
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Packaging Trend #2
• Global Supply Loops: With the increased growth of global vehicles,
the supply chain for these vehicle parts also needs to be global.
– New challenges for part protection, with the increased number
of miles the package travels
– Different modes have their own unique challenges (Truck, rail vs
ocean)
• Dunnage Impact: Getting the correct part protection is essential to
these long loops.
– Damage rates have to be minimized, due to the time and cost
associated with replacing damaged parts.
– Collapsibility or part flexibility versus expendable
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Packaging Trend #3
• Managing Transportation Costs: Need to understand the entire
supply chain to make the best decision on the correct packaging.
– Avoid optimizing one specific area, only to drive up the total
cost by negatively affecting other areas.
• Dunnage Impact: Cube utilization with the correct container for
the mode of transport is essential.
– Accounting for the required level of part protection can lead to
different material options and can impact the number of parts
than can fit in the container.
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Packaging Trend #4
• Standardization on Packaging: OEMs and suppliers are pushing to
reduce the overall number of packaging SKUs to simplify the
management process and, in theory, increase the amount of reuse.
• Dunnage Impact: Designs need to accommodate multiple parts so
they are not limited to a specific part or supplier
– Two solutions:
• Using a very simple design (divider set) can keep the
dunnage cost down, but can reduce the cube utilization and
part protection
• More sophisticated engineered design will drive up the cost
of the dunnage, but will reduce the impact on the cube
utilization and part protection
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Standardization Examples
• North American Standard versus Metric
– NA Standard 48” x 45”
– Metric 1000mm x 1200mm
• Make the correct decision for the entire
supply chain
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Packaging Trend #5
• Moving to Small Lot: Moving away from bulk quantities to handheld tote quantities for certain size parts/components.
– This can allow for better utilization line side and can reduce
inventory space.
– This change does increase the velocity of the packaging through
the supply chain.
• Dunnage Impact: Different ergonomic considerations need to be
taken into account when designing dunnage for bulk containers
than handheld containers.
– Pack density and part protection remain important, but the way
you achieve them can be drastically different.
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Common Materials and Applications
• Foam and Plastic Inserts
• Flexible Fabric Solutions
• Molded Foam Components
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Foam and Plastic Inserts
Materials vary widely in type of base resin, thickness and color. Plastic corrugated
and solid plastic sheets can be die cut and combined with all types of foam to
meet protection requirements.
Benefits:
• Flexible and less sensitive to part changes
• Fully flexible for L x W x H dimensions
• A variety of materials, thickness and colors
• Plastic corrugated or solid sheets
• Can be laminated with thin sheets of foam or fabric
to prevent product scuffing.
Popular Applications:
• Most common solution for a wide array of
Tier 1 and 2 components
• Typically placed into standard containers
• Critical “Class-A” protection option
• Smooth surfaced components
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Flexible Fabric Solutions
Fabric dunnage is industrial strength and skillfully sewn. Can be
used in combination with rigid materials to create unique
packaging solutions
Benefits:
• Flexible and less sensitive to part changes
• Easily accommodates part nesting for increased
pack density
• Fully flexible for L x W x H dimensions
• Variety of materials, thickness and colors
Popular Applications:
• Critical “Class-A” surface products
• Parts with complex geometry or curvature such
as, long trim parts, spoilers, mirrors, door
panels, etc.
• Designed for totes, bulk containers and steel
racks
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Molded EPP Foam Dunnage
Completely customer EPP foam trays, stand-alone totes and dunnage logs can help to
protect and separate sensitive products.
Benefits:
• Clean, smooth, one-piece construction
• Fully recyclable
• Fully flexible L x W x H dimensions
• Lightweight and ergonomically-friendly
• Durable to withstand sharp edges and protrusions
• Multiple densities and color options available
Tray Insert
Popular Applications:
• Critical “Class-A” surface products, like grilles,
fascias, & wiper blade assemblies
• Irregular shaped parts
Stand-Alone
Tote
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Implementation Best Practices
• Analyze your entire global supply chain to find opportunities for re-use
• Understand different materials available and benefits
• Consider mode of transportation and shipping distance
• Design dunnage that meets protection requirements, while providing future
flexibility
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Q&A
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