DS Smith cuts handling by 30%
April 1st 2005 By completely reviewing its supply chain, a major manufacturer of chinaware reduced its handling operations by nearly 30%.
Working closely with DS Smith Packaging at Clay Cross, a 12-month investigation led to the replacement of 35 pack variants in style, size and print with just two speciality tote trays.
The full product range is manufactured at separate distinct potteries and supplied to a central warehousing and distribution centre packed in plastic tote trays. The items were then removed and stored on shelving awaiting order picking, when tote trays were again used to supply the packing department, where boxed were erected, filled and sealed for unitisation before distribution. The key element for the success of the new distribution system was the design of a corrugated tote tray, delivered in the flat. The registered tray, “CorrTote” is machine erected, has triangulated corner strengtheners and reinforced glued end tabs giving a stacking performance in excess of 700kgs. The tray comes in two height variations and has stacking lugs that interlock with the upper tray when multistacked up to ten high. For shipments an optional, simple lid cover can be used on the top tray before shrink wrapping to a pallet.
Chinaware is now delivered to and stored at the DC in corrugated tote boxes.
As the global markets now receive the same tray quantities, product is order picked and shipped using the same tray, reducing handling operations by nearly 30%.
With the standardisation of the distribution tray and optimum fit to the standard 1200x1000mm pallet nearly 25% more product can be shipped. More articles from DS Smith Packaging: | 
