About Us
About PVP
What's New
Points of Difference
Recycling
Case Studies
Contact Us

Line Break

PDF Downloads

PDF Downloads
 

“C” & “B” Pillar Case Study


Our client is currently ramping up to ship 400,000 KL “C” & “B” Pillar parts. The existing packs are expendable corrugated and die cut crosslink foam layer pads. When the production is at full capacity our client will require:

  • 380 of KL “B” Pillar parts per day
  • 208 of KL “C” Pillar parts per day

The PVP design team spent several hours reviewing the existing simple part to see if we could take cost out of the packs. The results are as follows:

KL “C” Pillar Pack Redesign

  • We reduced all four (4) trim racks by 2”.
  • We reduced the foam density from 2” to 1.5”.
  • We redesigned the corrugated layer pad to interlock, reducing overall width by 2”.

KL “B” Pillar Pack Redesign

  • The second trim rack height was reduced from 6” to 3.5”.
  • We reduced the foam density from 2” to 1.5” each foam.
  • We redesigned the corrugated layer pad to interlock, reducing overall width by 2”.
  • We increased the pack density from 11 pieces to 12 pieces.

We offered to ship the two (2) packs in a reusable self-sticking metal rack to replace the 150 stock boxes needed each week.

Note, the custom reusable metal rack will hold,

  • 48 packs of the KL “B” Pillar part
  • 42 packs of the KL “C” Pillar part

The End Result

By paying close attention to small pack improvements we were able to reduce the per piece price by over 50% on both "B" and "C" pillar packs.


Old Packs

Rollstamp Old   Rollstamp Old

Redesigned Packs

Rollstamp New   Rollstamp New