Make the unseen cost visible.

Current stateThe existing corrugated insert system was complex, slow to assemble, and required substantial warehouse space. Multiple shock-absorber configurations also made it difficult to maintain a standardized set of inserts.

ObjectiveReduce packing time, storage requirements, and total cost while securely supporting the shock absorber.

Current stateThe existing process required packers to select and position loose foam while managing multiple packaging SKUs. The motor and accessory cable also needed to remain separated and protected from carton contact.

ObjectiveCreate a faster, repeatable suspension system that consolidates everything into one carton.

Current stateLong foam rails occupied excessive storage space and slowed the packing process. Oversized cartons also increased dimensional freight costs while allowing unnecessary product movement.

ObjectiveProtect only the vulnerable fixture ends using packaging produced on demand.

Current stateThe existing process relied on wood blocks and hand-cut inserts that were labor-intensive, expensive, and difficult to standardize. Bulky packaging components also consumed storage space and created inconsistent protection around the irregular part.

ObjectiveProduce recyclable paper cushioning on demand and use it to support the load points and fill remaining voids.

Current stateEach shipment consumed disposable ESD bags, foam pads, and corrugated cartons while requiring repetitive manual packing. This created significant material waste, labor expense, and packaging inventory.

ObjectiveReplace the one-way pack with a conductive, stackable system designed for repeated closed-loop use.

Current stateThe current EPS-and-gel-pack system requires substantial warehouse space, takes approximately 16 minutes to assemble, and creates avoidable thermal-excursion risk for high-value biologic shipments.

ObjectiveQualify one repeatable 4-liter PCM/VIP shipping system capable of maintaining a 2–8°C parcel profile for up to 120 hours.

Current stateThe existing seafood packout uses bulky EPS containers and four gel packs per order, increasing storage requirements, dimensional freight, material consumption, and disposal complexity.

ObjectiveCreate a right-sized 48-hour cold-chain parcel using a folding paper thermal liner, a sealed seafood pouch, and two qualified cool packs.

Current statePackers currently measure, cut, fold, fill, and tape oversized parts cartons by hand, adding labor while shipping unnecessary air and consuming excess void fill.

ObjectiveAutomatically scan each compatible packed carton, trim it to the measured product height, fold the flaps, and apply tape in one inline process.

Current stateThe current apparel process requires employees to open mailers, load garments, remove adhesive liners, close packages, and apply separate shipping labels across approximately 1.8 million annual orders.

ObjectiveCombine roll-fed bag presentation, garment loading, direct-on-bag printing, and heat sealing in one assisted workstation.

Current stateThe current end-of-line process relies on repetitive manual case stacking and hand wrapping, leading to ergonomic exposure, inconsistent pallet patterns, variable film use, and unstable-load exceptions.

ObjectiveUse a recipe-controlled cobot to build each pallet and an automatic stretch wrapper to apply a repeatable containment profile.