Medical device manufacturer transforms product packaging

A new plasma donation machine line became an opportunity

An additional opportunity for the project revolved around the replacement of older machines. When a new unit was shipped to the customer site, the older unit was returned for refurbishment. This reverse logistics loop hadn’t been considered from a packaging perspective.

Because it was a different shape, the older model did not fit into the packaging materials for the newer machines. Often these to-be-returned machines were loaded — unpackaged and unprotected — directly onto pallets. These were stretch-wrapped and sent via a less-than-load (LTL) shipment to the corresponding refurbishment facility. Returned unit damage was predictably and needlessly high.

As COVID-19 swept the world, sea containers became increasingly expensive, and prices approached all-time highs. This trend continued, driving the need for greater container density and reduced shipping costs.

The manufacturer knew that proactive action was necessary to address current issues and forestall unforeseen consequences. The packaging system for the new generation of machines presented the ideal opportunity to achieve all these goals.

Tackling the issues with one coherent system

To start the project, NTT DATA audited and mapped the anticipated supply chain of the new machines and the return of the older, to-be-refurbished products.

The pandemic complicated matters as lockdowns meant that onsite visits — for supply chain mapping, direct inspections of packaging, shipment facilities and other evaluations — weren’t an option. Instead, a revised mapping process allowed the isolation of hazards and opportunities throughout the supply chain.

Initial designs were developed in SOLIDWORKS and prototypes were assembled at NTT DATA’s packaging development center. Pre-qualification tests in the packaging lab found a need for an additional packaging component to stabilize the product during impacts. The protective packaging was custom designed, allowing for a standardized configuration that could adequately protect older machines during the return process.

A final round of testing followed, using materials obtained from original equipment manufacturer (OEM) packaging suppliers. No issues were found, and the design moved into the production phase. Assembly documentation was developed, and international alignment meetings were held to explain the straightforward assembly process.

Due to the need for greater shipping density and the dimensional limitations of sea containers, the size of the product and standard pallet sizes, the team optimized the final packaging to suit a pinwheel four-pack on a 45×45 pallet design.

Initial container deliveries arrived two months later than anticipated. Despite delays and exposure to in-transit forces, all packaging and products arrived undamaged.

The project’s achievements exceeded all expectations in waste reduction, cost savings and product damage control.