[Cost Reduction Case] Standardization of 16 types of automotive parts using 2 trays.

Standardizing the trays has increased the quantity (improved loading efficiency).

This is a case of improving the transportation efficiency of parts when launching 16 types of automotive component valves. The customer's concern was that creating a tray for each valve would require the production of 16 trays, which posed challenges in terms of cost and management. They were also considering whether it was possible to increase the number of valves stored in each tray. Concern 1: For 16 types of hydraulic valves for automotive parts, 16 trays of different shapes were being used. Concern 2: The current product stores 20 valves in one tray. [Packaging Improvement Initiatives] We received data on the 16 valve products and proceeded to consider standardization through 3D design, deciding to change the storage method from horizontal to vertical. As a result, we were able to accommodate the 16 valve products with just two types of trays (standardized trays). By changing from horizontal to vertical storage, the capacity increased from 20 to 25 valves per tray, resulting in a 20% increase in tray loading efficiency. *For more details, please refer to the PDF.

Cushioning materialtrayOther packaging materials