property of orbis corporation | optimize global shipments with customized dunnage solutions scott...

Property of ORBIS Corporation | www.orbiscorporation.com

Optimize Global Shipments with Customized Dunnage Solutions

Scott Krebs and Jenny Orszula


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Global Dunnage and Packaging Solutions

• Value of reusable dunnage for the global automotive industry • Current automotive packaging trends and the

impact that dunnage has on each:– Shipping new materials– International supply loops– Managing transportation costs– Standardization– Shift to small lot

• Review of common materials and applications


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Review of Shipping Forms of Reusable Packaging

Unit loads of pallets, totes and top caps

Bulk Containers

Steel Racks

Collapsible Totes

Custom Protective Dunnage

Today’s focus is protective dunnage.


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Why Reusables and Dunnage for the Global Automotive Industry?

• Better part protection• Improved pack density• Reduced waste• Better part presentation• Standardized work flow/line side • Optimized transportation


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Current Global Packaging Trends

• New Materials Being Shipped• International Supply Loops• Managing Transportation Costs• Standardization• Shift to Small Lot


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Packaging Trend #1• Shipping New Materials: Challenges of handling and protecting the

new materials being used in vehicles to reduce the total vehicle weight and increase MPG– Aluminum replacing steel– New light weight resins for plastic parts

• Dunnage Impact: Through testing, new dunnage materials have been developed that outperform the traditional dunnage materials when used to protect the new lightweight automotive parts.


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Packaging Trend #2• Global Supply Loops: With the increased growth of global vehicles,

the supply chain for these vehicle parts also needs to be global.– New challenges for part protection, with the increased number

of miles the package travels– Different modes have their own unique challenges (Truck, rail vs

ocean)

• Dunnage Impact: Getting the correct part protection is essential to these long loops. – Damage rates have to be minimized, due to the time and cost

associated with replacing damaged parts.– Collapsibility or part flexibility versus expendable


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Packaging Trend #3• Managing Transportation Costs: Need to understand the entire

supply chain to make the best decision on the correct packaging. – Avoid optimizing one specific area, only to drive up the total

cost by negatively affecting other areas.

• Dunnage Impact: Cube utilization with the correct container for the mode of transport is essential.– Accounting for the required level of part protection can lead to

different material options and can impact the number of parts than can fit in the container.


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Packaging Trend #4• Standardization on Packaging: OEMs and suppliers are pushing to

reduce the overall number of packaging SKUs to simplify the management process and, in theory, increase the amount of reuse.

• Dunnage Impact: Designs need to accommodate multiple parts so they are not limited to a specific part or supplier– Two solutions:

• Using a very simple design (divider set) can keep the dunnage cost down, but can reduce the cube utilization and part protection

• More sophisticated engineered design will drive up the cost of the dunnage, but will reduce the impact on the cube utilization and part protection


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Standardization Examples

• North American Standard versus Metric– NA Standard 48” x 45”– Metric 1000mm x 1200mm

• Make the correct decision for the entire supply chain


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Packaging Trend #5• Moving to Small Lot: Moving away from bulk quantities to hand-

held tote quantities for certain size parts/components. – This can allow for better utilization line side and can reduce

inventory space.– This change does increase the velocity of the packaging through

the supply chain.

• Dunnage Impact: Different ergonomic considerations need to be taken into account when designing dunnage for bulk containers than handheld containers. – Pack density and part protection remain important, but the way

you achieve them can be drastically different.


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• Foam and Plastic Inserts• Flexible Fabric Solutions• Molded Foam Components

Common Materials and Applications


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Foam and Plastic Inserts

Benefits:• Flexible and less sensitive to part changes• Fully flexible for L x W x H dimensions• A variety of materials, thickness and colors• Plastic corrugated or solid sheets• Can be laminated with thin sheets of foam or fabric

to prevent product scuffing.

Materials vary widely in type of base resin, thickness and color. Plastic corrugated and solid plastic sheets can be die cut and combined with all types of foam to meet protection requirements.

Popular Applications:• Most common solution for a wide array of

Tier 1 and 2 components• Typically placed into standard containers• Critical “Class-A” protection option• Smooth surfaced components


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Flexible Fabric Solutions

Benefits:• Flexible and less sensitive to part changes• Easily accommodates part nesting for increased

pack density• Fully flexible for L x W x H dimensions• Variety of materials, thickness and colors

Popular Applications:• Critical “Class-A” surface products• Parts with complex geometry or curvature such

as, long trim parts, spoilers, mirrors, door panels, etc.

• Designed for totes, bulk containers and steel racks

Fabric dunnage is industrial strength and skillfully sewn. Can be used in combination with rigid materials to create unique packaging solutions


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Molded EPP Foam Dunnage

Benefits:• Clean, smooth, one-piece construction• Fully recyclable• Fully flexible L x W x H dimensions• Lightweight and ergonomically-friendly• Durable to withstand sharp edges and protrusions• Multiple densities and color options available

Popular Applications:• Critical “Class-A” surface products, like grilles,

fascias, & wiper blade assemblies• Irregular shaped parts

Completely customer EPP foam trays, stand-alone totes and dunnage logs can help to protect and separate sensitive products.

Tray Insert

Stand-Alone Tote


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Implementation Best Practices• Analyze your entire global supply chain to find opportunities for re-use

• Understand different materials available and benefits

• Consider mode of transportation and shipping distance

• Design dunnage that meets protection requirements, while providing future flexibility


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Q & A

property of orbis corporation | optimize global shipments with customized dunnage solutions scott...

Documents

new dunnage materials

correct packaging

traditional dunnage

plastic parts dunnage

global supply loops

new challenges

number of parts

rail vs ocean dunnage