Packaging Application: Aisin USA is a leader in the design and production of high-quality automotive components, including
door frames, roofs, latching systems, brakes, engines, seating and trim molding, for today’s leading automakers (OEMs) and suppliers. At its Seymour, Ind., facility, it runs more than 275 production lines a day and fills more than 100 truckloads. As a Tier 1 supplier, Aisin manufactures components from beginning to end and ships directly to major automotive manufacturers. Aisin also acts as a Tier 2 supplier, creating OEM components from parts supplied entirely by vendors.

Packaging Challenge: In addition to the sheer volume and complexity of processes, Aisin must meet size and weight guidelines for shipping, while maintaining part quality and integrity. Using expendable corrugated packaging was difficult and costly. Also, Aisin often had odd-shaped parts thatwere larger than standard container sizes and finding containers to accommodate unique sizes was critical to optimizing part shipments. With so many parts in process, there were a substantial number of containers in storage so the container sizes needed to be versatile enough to fulfill a variety of needs throughout the system at any given time.

Packaging Solution: After analyzing Aisin’s system and flow of material, ORBIS recommended the plastic reusable Stakpak CrossPak™ container system. The straight-wall design holds more parts per container and because their rigid walls won’t sag or bend, they offer tremendous part protection. The CrossPak has an innovative interlocking bottom that allows the combination of different containers with different heights to be stacked on a 45“ x 48” pallet, creating a modular load so more parts reach the line in the order and quantity needed. ORBIS’ Cut-N-Weld™ technology adds length, width or height to an existing container to hold larger, odd-shaped parts. All ORBIS containers feature an attached cardholder, so Aisin can easily track containers and maintain inventory.

Results:

• Reduced packaging costs - through reusability
• Optimized transportation
• Enabled tracking and inventory control
• Improved part protection
• Improved part density
• Optimized storage