Parts stacking reinforcement

The client is a contract manufacturer of electronics parts, shipping in full pallets stacked up to six high in the warehouse.

What they used: cheap thin board to hold cost down. Boxes began collapsing at the fourth layer, damaged parts had to be reworked and sorted, and warranty claims came in every month.

What we changed: board grades back-calculated from the actual stacking height, switched to five-ply double-wall with higher edge-crush strength; palletised shipping, box sizes narrowed to three specs, standardised board grades so the warehouse stacks by box type.

Result: damage rate down 90%, warranty claims down to zero, and goods go straight into stock after outgoing inspection instead of being re-sorted.