From SKU Complexity to Corrugate Consolidation, Unlocking Efficiency & Cost Savings
Client Overview
A high-volume manufacturer managing tens of thousands of SKUs was developing new packaging in isolated business units. Without centralized oversight, corrugated formats were never consolidated across the organization, creating complexity, operational inefficiencies, and avoidable cost burdens across procurement and production.
The organization needed a structured approach to standardize corrugate packaging, improve purchasing leverage, and streamline operations without disrupting production continuity.
The Challenge:
Operating in silos led to three major inefficiencies:
- Diminished purchasing power due to fragmented corrugate specifications
- Unnecessary production changeovers driven by excessive format variation
- Higher-than-necessary inventory costs from maintaining too many packaging formats
With thousands of SKUs and decentralized packaging decisions, consolidation required both data clarity and engineering rigor.
Adept's Approach:
Adept implemented a data-driven packaging optimization strategy designed to drive both operational efficiency and cost savings:
- Supported the procurement team in aggregating and validating SAP data through collaboration with the client’s IT department
- Grouped thousands of products into standardized size categories capable of utilizing the same corrugate structures
- Designed RFQ-ready corrugate drawings for each size grouping (.PDF and .ARD formats)
- Created a user-friendly corrugate drawing database to prevent the proliferation of new, redundant designs
- Validated new designs using ISTA testing protocols to ensure performance integrity
- Leveraged RFQ responses to build a predictive pricing model, accelerating future pricing turnaround
This structured consolidation approach balanced engineering performance with procurement strategy.
The Impact:
The packaging optimization initiative delivered measurable operational and financial improvements:
- 40% reduction in existing corrugate packaging formats
- 80% reduction in casting turnaround time
- 10% reduction in corrugate and inventory costs
By aligning engineering, procurement, and operations, the client achieved stronger purchasing leverage, streamlined production, and a scalable corrugate strategy designed to support future growth.
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