Client Successes

An Unexpected Solution for a Common Problem

Operating a production line with overtime hours was still not enough for this personal care manufacturer to meet the demand for product. The company hired Wachler Engineering to specify new equipment to meet the challenge. After a careful process audit, Wachler Engineering determined new production equipment was not the answer.

By adding two additional workers to the line — during normal working hours — and changing the way personnel were operating, production speed was increased sufficiently to eliminate overtime and backorders. The result was an immediate reduction in the total production cost, a more ergonomic work environment and the avoidance of a costly capital expenditure.

Meeting the Challenges of Compliance and Sustainability

When the packaging of this chemical company did not meet the California environmental regulations, Wachler Engineering was hired to bring the rigid plastic containers into compliance and improve sustainability.

By identifying specifications to benchmark the current situation, Wachler Engineering was able to locate opportunities to improve the package design, consolidate the total number of packages, and reduce the number of suppliers.

With fewer suppliers, and improved bottle designs, the company not only became compliant but also gained other sustainable benefits:

• $600,000 cost savings
• 10% source reduction or 25% PCR
• improved pricing and lead time
• favorable supply agreements
• quality performance metrics

Optimizing Packaging for Cost Reduction and Sustainability

In the food service industry, reducing costs are a must for staying competitive. Sustainability initiatives offer many opportunities for optimizing product packaging and lowering expenses when manufacturers take the time to properly analyze the supply chain.

Hired by a large food manufacturer to help uncover savings opportunities, Wachler Engineering audited the supply chain and gathered all the packaging specifications. The review determined that focusing on source reduction and cube utilization would provide the most immediate gains for sustainability. As a result, smaller packages were created to reduce material usage and allow more product to fit on each pallet.

The effort created a savings of over $1 million in packaging and transportation costs without incurring any capital expenditure. In addition, greenhouse gases were reduced by 290 tons from optimized freight and packaging manufacturing. Now that's sustainability.