How to optimise the packaging process to reduce the high rate of complaints?
Our client, a world market leader in home improvement and craftsman supplies with its own logistics centre in Germany, was looking for a way to reduce the high rate of complaints his clients was receiving.
Our client, a world market leader in home improvement and craftsman supplies with its own logistics centre in Germany, was looking for a way to reduce the high rate of complaints his clients was receiving.
The client's challenge
Approx. 8,000 parcels are dispatched per day, packed manually at 35 packing stations. 600 tons of bogus paper are used as filling material, which corresponds to 1,200 pallets of 500 kg each.
Employees from the packaging department ensure the material supply to the packing stations. Although the intralogistics are good - an automatic high-bay racking, package conveyor lines and a carton sealing system are available - the packaging remains the “shipping bottleneck”. In addition, the customer is disturbed by the high rate of complaints.
The Antalis solution
A sensor-controlled channel conveyor system now automatically supplies all packing stations with air cushions as filling material. The channels are fed from a total of three machine islands, to which special supply staff deliver packaging materials. This means that the employees at the packing stations always stay in their place, which increased efficiency by 8 percent.
Because filled air cushions are now used on site, the pallet throughput of the material supply could be reduced from 1,200 to 300 pallets. In addition, the complaint rate was reduced to less than 0.1 percent, as the air cushions offer a stable volume even under load compared to crumple paper. This ensures permanent cost control.
The process
- Project start through initial consultation with the customer
- Planning of a solution by the product managers
- Presentation of possible solutions to the customer
- Decision: Integration of an Automatic Delivery System with use of air cushions)
- Planning of the installation
- Installation and commissioning of the plant, staff training
Advantages
COST REDUCTION
In addition to reducing intralogistics costs by 75%, packaging throughput is increasing by as much as 8%.
ERGONOMIC
Better ergonomics at the packing station make packing easier and faster for employees.
ENVIRONMENTALLY
FRIENDLY
Fewer deliveries reduce CO2 emissions by 75%. Packaging waste has also been reduced by four fifths.
Services provided
Complaint identification with simultaneous analysis and optimisation of packaging process.
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