Company: Ryobi

Packaging Application: Storing materials for assembly line setup at Ryobi Motor Products Corporation

Packaging Solution: Assembly line setups took too much time. One out of five setups required an additional half-hour to locate misplaced tooling which were stored in eight metal racks on the shop floor.

Packaging Solution: ORBIS worked with Ryobi to recommend a 40" x 48" plastic reusable bulk container. A lift truck moves the containers from a storage area to the appropriate assembly line. A master list identifies which setup parts are in each container and where the container is stored. By checking a station control document, setup specialists are able to install the right tooling and fixtures for each station in the line. The empty containers can be quickly collapsed to a fraction of their height for space saving storage until needed.

Product: 40" x 48" x 39" and 40" x 48" x 29" bulk containers

Results: Setup time has been reduced by 15 minutes. This savings provided a 6 month payback on investment and downtime has been cut by 10%, providing additional $33,000 annual savings.