Company: Ford Motor Company

Packaging Application: Shipment of four-cyclinder engines across the globe, from Ford's powertrain plant in Mexico to its
assembly plant in China.

Packaging Challenge: Global manufacturing in the automotive industry brings new packaging needs based on much longer distances in transportation. Engines, as one of the heaviest individual components in vehicle manufacturing, set especially high demands on packaging. Their transportation across the globe requires precise and custom-fit packaging. Packaging must be be durable enough to last the long transit time and repeated trips.

Packaging Solution: The packaging for Ford’s four-cyclinder engine needed to address various requirements, besides
strength and durablity to sustain the long journey. Product protection, easy handling for manufacturing, economical design and also adaptability to suit both Mexican and Chinese plant handling systems were just some of the requirements.

The assembly plant, a joint venture between Ford and ChangAn in Chongqing, China turned to its existing packaging supplier, ORBIS, to find a solution that could be addressed from a global and local perspective.

ORBIS got to the task by applying experience from both its Chinese and Mexican design and engineering team. Having experts visit the shipping Ford facility in Mexico, and also the receiving facility in Chongquing, China, focus was put on providing Ford with a custom solution that would truly fit both locations.

ORBIS' Chinese team created a prototype to test the entire shipping loop. The prototype was first sent without load to Chihuahua to simulate the empty return loop, and then sent fully loaded on the Chihuahua-Congquing route.

At both locations, ORBIS' engineering teams were evaluating and monitoring performance of the packaging, which provided immediate feedback and insight into this unique transportation route. ORBIS' Mexican team also provided immediate service and support to Ford during start-up of the project in Chihuahua.

Results:

• Superior Product Protection: The pack offers superior product protection since the engine cell is profiled to the exact dimension of the engine. Such a rigid packaging system forces the engine to remain in position, and during movement or vibration the engines will not come into contact with each other. 
  
• Improved space utlization: The metal racks can be stacked 2 high and are collapsible,allowing for efficient space utilization during sea transit. Racks and engine cells are manufactured by ORBIS locally in China.

Ford’s project asked for experts of multiple packaging materials in multiple locations. ORBIS' design team was able to respond with a design that incorporated metal and roto-molded plastic, supported with experienced local design and engineering teams in Asia and Latin-America.

Ford received a packaging system that is truly custom. This packaging solution is providing unbeatable protection for criticial high value components, where damage would otherwise result in unacceptable time and cost consequences
for Ford’s business.