ISSUE
Carton SKU Count

SOLUTION
Cartonization Software

DHL Supply Chain location shaved $45k off of their annual corrugated spend with right size packaging dimensions.

”Going from 22 box SKUs to 6 has streamlined our entire workflow.

Cole KraesigDHL Supply Chain

CASE STUDY

A DHL warehouse used 22 different box sizes to ship out orders. This slowed down workers packing boxes. It also took extra time to track box inventory.

We used packchain’s carton optimization software to find that most product dimensions were listed at 1 x 1 x 1. This meant that the warehouse management system could not help staff pick the right box. Our study also found that using fewer box types would ship less air.

Over three months, we captured exact product dimensions inside an existing Hospital workflow. Then we ran another analysis with our cartonization software. With accurate product dimensions, we picked six new box sizes. This cut the air being shipped from 42% to 38%.

Six new box sizes cut costs $45,000 and right size packaging cut air in boxes by 9.5%. Hospital rates also dropped from 40% to under 1%, making work faster and workers happier.

Carton Optimization

73

%
Reduction in box SKU count

Annual Savings

$

45,000

Volume discount on new box sizes