Redesign Eliminates Box Failure

and Optimizing Storage and Freight


Cross Container was brought in to solve a box failure problem that plagued the customer throughout his supply chain.  This manufacturer of truck bumper part assemblies was experiencing failure at various points in the distribution cycle all stemming from poor product nesting and layering.  The nesting pattern produced a box foot print that exceeded the required shipping pallet.  The pallet overhang sheared off the stacking strength capabilities of the box structure resulting in stacking failure.


PRIMARY CHALLENGE: Realign the product nesting and design a box size to improve the stacking performance eliminating box failure.  The goal is to eliminate product damage and customer rejections.

Stack Problem
Initial Box Stacking Problem

SECONDARY CONSIDERATIONS: Improve internal handling, storage and truck utilization for reduced freight costs.

THE SOLUTION: Cross Containers’ design orientated from the pallet size, yielding a new box size leading to a new product configuration. The box count remained at 24 bumper pieces, but they were reoriented to two nested layers with a divider pad.


New Box Design

RESULTS: Cross redesigned the box size and product orientation.  Now the boxes stack within the pallet area allowing two pallet wide loading on trailers, maximizing truck utilization and freight costs.  Customer rejections due to box failure were eliminated.

REDUCED COSTS: Box cost was maintained while reconfiguring the new pallet stacking.  Reduction in cost was realized by eliminating product damage  from box failure.  Additional savings were achieved through freight savings.  The new box size allowed the doubling of product shipped per truckload, increasing from 5,000 pieces to 10,000 pieces.