Results
69%
Increase
in load per container (from 92 to 169 units)
30%
Reduction
in packing cycle time
27%
Cost Reduction
worth INR 9.5 million annually
Context
When you’re the world’s largest manufacturer of financial transaction equipment, even a small inefficiency compounds into millions.
Their packaging design—built years ago for stability—had never been re-examined for efficiency. Containers went half-filled, pallets mismatched, and logistics became an invisible drag on profit.
Challenge
Every teller-machine subassembly shipped safely, but expensively.
Packaging had become a fixed cost nobody questioned—until it started costing too much. The goal wasn’t to trim the edges; it was to rethink the entire load-flow system from design to dock.
Objective
To design packaging for multiple sub-components that:
- Maximizes every cubic foot of container space
- Integrates cleanly into the client’s lean manufacturing line
- Reduces cost without adding complexity
The SUPERPACKS Intervention
SUPERPACKS flipped the problem on its head—literally.
We implemented a reverse packaging approach, redesigning from the loading dock backward.
Pallet sizes were recalibrated to achieve perfect container utilization, and modular boxes were created for smoother pallet handling and line integration.
The new design used minimal wood and EPE foam, engineered for strength, impact absorption, and cost efficiency.
The system didn’t just fit the product; it fit the client’s manufacturing rhythm.
Results That Compounded Like Interest
- 69% increase in load per container (from 92 to 169 units)
- 30% reduction in packing cycle time
- 27% cost reduction — worth INR 9.5 million annually
For a company that processes transactions by the millisecond, this was efficiency applied to matter itself.
Lean isn’t a process — it’s a design philosophy.
SUPERPACKS turns every square inch of your supply chain into an asset.
