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Custom returnable packaging trays. The easy way to help implement cost downs.
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4/17/02 1
NA 2002 On-Floor Seminar Series Welcomes You to Session 112
“Solving Work in Progress & Returnable Packaging Through Industrial Metal
Containers”Sponsored by: IMC&WDSpeaker: Todd Cozart
4/17/02 2
Returnable Containers Cost Justification
Todd Cozart
4/17/02 3
Why Do We Define Packaging?
• Quality• Cost• Order Planning• Standardization &
Modular• Manpower Planning• Inventory Control
4/17/02 4
Why Do We Define Packaging Cont’d
• Supplier Control• Workstation Layout• Warehousing• Housekeeping• Transportation
Efficiencies• Safety• Eliminate Surprises
4/17/02 5
Assemble Logistic Team
• Packaging Rep. • Materials Rep.• Transportation Rep.• Material Handling
Rep.• Production Rep.• Purchasing Rep.• Safety/Ergonomics
Rep.
4/17/02 6
Identify Commodities• QDC Evaluation
– Gather Historical Information:• Quality Concerns and High $
Reject Rates • Delivery Concerns, Internal and
External• Transportation Cost by
Commodities• Labor Cost by Commodities• Disposal Cost of Packaging
Material• Packaging Material Cost• Safety and Ergonomic Concerns
4/17/02 7
Prioritize Commodities
• Prioritize Based on Largest QDC Gains– $$$$$– Quality– Safety
• Hint - Large Parts Should Be the Targeted Parts
4/17/02 8
Concept Phase• Logistic Team Define:
– Project Time Line Per Commodity– Product and Process Requirements:
• Visit Workstation• Part Orientation• Quantity Targets Per Container• Container Size• Critical Part Characteristics• Weight limits• Loading/unloading requirements• shipping storage and handling
methods– Sketch or mock-up container concept
4/17/02 9
Preliminary Logistics Study
• Define Current Cost Vs Proposed Cost– Packaging Material Cost– Transportation Cost– Labor Cost– Disposal Cost– Inventory Cost
4/17/02 10
Define Direction
• Logistic Team To:– Review Logistics Study– Continue or Stop– Review Concepts– Preliminary Buy-in– Review & Update Timeline
4/17/02 11
Purchase Prototype Container
• Review – In Plant– At Supplier– Run Shipping Trial
4/17/02 12
Prototype Container
• Modify If Necessary• Update Timeline• Buy off in Writing
4/17/02 13
Finalize Logistics Cost
• Typical ROI Hurdle Rates Are:
– 25% to 35% Minimum Return on Investment for Cost Reduction Projects
– 15% ROI on Required Projects
4/17/02 14
Request Funds for Project
• Included in Justification Are:– Logistics Cost Savings– Savings Commitment From Supplier/plant– Three Container Quotes– Final Approval
4/17/02 15
Place Purchase Order
• Update Timeline
4/17/02 16
Container Samples
4/17/02 17
Logistic Pieces of the Pie
Packaging Transportation LaborDisposal Inventory Warehousing
4/17/02 18
Packaging Cost
P ackaging T ransportation L aborD isposal Inventory W arehousing
4/17/02 19
Packaging CostExample: Class 8 Truck Battery Box Lid
• Current Method:– Eight parts per crate– $34.00 per crate– $4.25 per part
• Proposed Method:– Twelve parts per returnable container– [($300/cont.)*(25 containers)/(8 yrs)] / (20 parts/day)*(250 Days/yr.) =
$0.19/Part
4/17/02 20
Transportation Cost
Packaging Transportation LaborDisposal Inventory Warehousing
4/17/02 21
Transportation Cost Example: Class 8 Truck Battery Box Lid
• Current Method:– Negotiated $425.00 one way (Truck Load Rate)– [($425/trailer)*(43% utilization)] / [(5 days supply)*(20 parts/day)] =
$1.83/Part
• Proposed Method:– Negotiated $625.00 Round Trip (Truck Load Rate)– [($625/trailer)*(14% utilization)] / [(5 days supply)*(20 parts/day)] =
$0.88/Part
Note: LTL uses rate per pound
4/17/02 22
Disposal Cost
Packaging Transportation LaborDisposal Inventory Warehousing
4/17/02 23
Disposal Cost Example: Class 8 Truck Battery Box Lid
• Current Method:– [(55 lbs./cont.) / (8 parts/cont.)]*($0.03/pound) = $0.21/Part
• Proposed Method:– Eliminated
4/17/02 24
Labor Cost Example: Class 8 Truck Battery Box Lid
• Current Method:– [($37.00/hr)/(60 min/hr)]*[(4 min/cont)/(8 parts/cont)] =
$0.31/Part
• Proposed Method:– [($37.00/hr)/(60 min/hr)]*[(2 min/cont)/(12 parts/cont)] =
$0.10/Part
4/17/02 25
Total Logistic Summary Pkg.
Cost/Part Transp. Cost/Part
Disposal Cost/Part
Labor Cost/Part
Total Cost/Part
Current $4.25 $1.83 $0.21 $0.31 $6.60
Proposed $0.19 $0.88 $0.00 $0.10 $1.17
Difference $4.06 $0.95 $0.21 $0.21 $5.43
$7,500 Investment / $27,150 Savings = ROI 28 %Note: Most companies use a tax & amortization schedule
4/17/02 26
Questions?