The extreme competitive pressure in the automotive industry places high demands on the most efficient packaging logistics possible. As part of a comprehensive process optimization, Delta developed a holistic optimization concept for a manufacturer of cylinder head covers.

The first step involved a detailed analysis of the current situation. In particular, the focus was on examining the internal transport routes, the packing processes and packing times as well as a check of the current packaging design.

With the help of the Delta Principle, weak points were uncovered and possible efficiency potential identified.

Previously, two different types of packaging were used for the internal and export shipping processes. This meant a packing time of 70 seconds per component for each packing process. The workflow was as follows:

1. Preparation of secondary packaging
2. Filling the secondary packaging
3. Storage in circulation packaging
4. Repacking in export packaging

Delta’s optimized version is now based on a single packaging made of mono-material (corrugated cardboard), which can be used for both internal circulation and shipping.
For the customer, this means significant improvements in the areas of

– Process time
– Workflow
– Packaging
– Sustainability

Thanks to Delta, the manufacturer will save 50 seconds of worker time per component in future and can dispense with a complete process step (repackaging).

The new packaging design, based on a mono-material construction, led to a more efficient use of space and a significant reduction in packaging costs. In addition, the use of 100% recyclable corrugated cardboard established a future-oriented, sustainable packaging process along the entire supply chain.