Issue:
Damage to products during handling and transport occurs mostly on top and bottom corners and edges.

Current Situation:
A lot of packaging material is used but much of it ineffectual because it was protecting part of the cabinet that was almost never damaged. A full length sleeve is used which does not provide adequate protection to the bottom corners and as it covers the product completely does not allow for easy identification.

Objective:
Re-configure packaging to increase cardboard material where it is needed and remove it where it is not required. This would reduce the amount of packaging materials used.

Improvement Initiative:
Design an identical top and bottom cap with thicker protection around the top and bottom edges of the product. The design of the packaging also needed to provide a greater level of protection on the front of the cabinet and was achieved by using triple thickness packaging.

Timing:
Implement progressively across the product range from June 2005.

Measurement:
Reduced product damage and packaging expenditure.