Case Study: How Custom Reusable Packaging Solved a Customer Challenge
At Area Tool & Manufacturing, we take pride in our efforts to be a problem-solving partner to our customers. We make every effort to help improve your results and your bottom line, whether that means recommending DFM changes for part savings or solution annealing for more efficient production. In some cases, it means looking beyond the machining itself.
That was the case with one customer recently whose parts arrived damaged from their handling during shipment. Rather than treating it as an issue outside of our control, we worked with them to find a better solution. Learn how we implemented a custom reusable packaging system to protect their parts and improve their results.
The Challenge: Repeat Shipping Damage
This customer placed blanket orders with us for scheduled monthly shipments of the same part. However, after parts were damaged in transit multiple times, they spoke to us about the problem they were facing.
The issue was particularly serious because the parts featured external threads on the outer diameter. Even minor damage to those external threads could make the parts unusable. Although we were able to repair the threads on the affected parts, the situation still added to the customer’s timeline. We wanted to find a permanent solution to prevent it from happening again rather than helping them recover after the fact.
The Solution: Custom Reusable Packaging
To solve the issue, we partnered with Amatech, a custom packaging company in Erie, PA. We provided sample parts and explained quantity and packaging requirements. Based on that information, they developed a custom reusable packaging concept and gave us drawings for approval.
The solution was specific to our customer’s part. It prevented part-to-part contact to protect the threaded features and create a more reliable method of recurring shipments.
The Outcome: Safer Parts and a Deeper Partnership
The process with reusable packaging is straightforward. We ship the packaged parts to the customer, they remove them, and when the packaging is empty, they simply send it back for reuse.
This system has now been used for shipments more than a dozen times with no part damage, and the packaging itself has held up extremely well. Because the packaging is reusable across many orders, the cost is spread over time, meaning it adds very little cost to a project.
This partner had already trusted our CNC machining. But now, they saw how every detail mattered to us in ensuring their satisfaction.
When Custom Packaging Makes Sense
This type of packaging is not necessary for every project. Very small parts may only require simpler protective methods, such as bubble wrap or standard off-the-shelf options like “egg crate” packaging. But for parts that are mid-sized to large and include delicate or easily damaged features, custom reusable packaging can be worth exploring.
We evaluate projects on a case-by-case basis, considering part geometry and shipment frequency.
Looking for Improvement Beyond Precision Machining
At Area Tool & Manufacturing, continuous improvement is our mindset. As an ISO 9001-certified shop, we are always looking for opportunities to improve quality and reduce waste.
Sometimes that improvement comes from the machining process itself. Sometimes it comes from packaging, shipping, or another step that others might overlook. Either way, our goal is the same: to be a reliable partner who helps solve problems and supports long-term success.
What can we do to solve problems for your next project? Contact us to discuss today!
