hormel foods
SITUATION:
Hormel’s Jennie-O product was leaching protein between its plastic bag and corrugated box. Jennie-O was increasing the gage of the current barrier bag hoping to resolve the issue, but after months of production, the problem persisted but at a smaller rate.
PROPOSAL:
AIM was tasked with finding a better solution to the process while reducing the cost of the current bags in use.
SOLUTION:
AIM completed an audit of the process workflow and material usage, and proposed a solution of using a double lined barrier along with changes in the process that improved clamps used to retain the bag around the corrugated box as well as upgrading the box assembly without staples. Also modified were fill stations to fill the box using a funnel-style plastic to increase the drag while filling until only 40 percent full. This change in process decreased the damage during loading and decreased spillage from filling.
OUTCOME:
The overall improvement saved in-process waste, decreased packaging costs, and decreased labor costs. Hormel’s income was impacted by saving $250,000/year.
rainbow furniture
SITUATION:
One of Rainbow Furniture’s new products was experiencing 30 percent product damage upon delivery.
PROPOSAL:
Aim was tasked with working with the transportation company, the manufacturing company and the end customer to reduce freight claims and product damage, and to increase customer satisfaction.
SOLUTION:
AIM completed an audit of the process workflow, material usage, product handling, and finished product presentation, which revealed that the product boxes were opening and allowing the internal cushioning to shift during transit. Aim proposed using a more aggressive and wider tape to seal the boxes – a tape that would be appropriate for the company to continue using corrugated boxes. This resulted in using half the amount of tape to properly seal the boxes. Aim also proposed inserting foam and corner boards for better product protection and stability during transit.
OUTCOME: