Kitting & Hand Assembly
Case Study: Hurricane Relief Meals
The Challenge
Mobilize partners and teams quickly to assemble 150,000 grocery boxes for Hurricane Maria disaster relief.
The Solution
Immediately stand up a 100+ person operation with leased space, equipment, conveyors and goods.
The Results
‘All-hands’ team effort where Productiv packaged and delivered 2.7 million meals in just 33 days to citizens in Puerto Rico. See the team in action here.
Packaging
Case Study: Repackaging Paper Goods For Retail
The Challenge
Operational inefficiencies and an over-reliance on temp workers were driving up labor costs with no output gain.
The Solution
Using fixed unit pricing and lean-engineered workflows, Productiv implemented an on-site program to create efficiencies and reduce costs.
The Results
Over 3 million cases of product with 300 unique SKUs are processed annually for 35% annual labor savings.
Point of Purchase (POP) Displays
Case Study: Building Stand-up Displays
The Challenge
Client was losing track of perishable inventory and had excess corrugated displays for fast-growing product line.
The Solution
Implemented Productiv’s WMS within 2 weeks. Combined WMS data with a full inventory count to sort by batch/lot and quickly build displays using lean-engineered processes.
The Results
Process management and inventory discipline reduced total materials by 25% and excess materials by 90%.
Custom Fulfillment
Case Study: Health & Beauty DTC Ecommerce Fulfillment Program
The Challenge
New ecommerce site was growing rapidly. Moving from start-up to 5,000 orders/day, there was a substantial order fulfillment backlog.
The Solution
Built end-to-end fulfillment operation with OMS and WMS: inventory system, integrated EDI, shipping, etc. and efficient pick pack line in order to provide competitive pricing.
The Results
Shipped more than 450K orders in first 4 months to handle demand backlog, stabilize fulfillment and aid customer retention. Achieved platinum 99.999% accuracy rating.
4PL and Turnkey Services
Case Study: FBA, Ecomm & EDI
The Challenge
Client needed turnkey fulfillment service for Amazon FBA, B2C and EDI into retail on short timeline in order to meet growing demand and orders from global retailers.
The Solution
Productiv onboarded the account and used process engineers and IT staff to quickly integrate WMS with ERP and then set up EDI portals with major retailers, domestic and international shipping for B2C, and an Amazon FBA program.
The Results
Currently achieving on-time and accuracy SLAs while distributing client’s products globally within 2 months.
Fill Lines
Case Study: Improving Throughput For Global Health & Beauty Contract Manufacturer
The Challenge
Manufacturer of health and beauty products was growing and demand for output was exceeding current capacity.
The Solution
After a trial with Productiv teams, supervisors and processes, our on-site workforce has grown to manage over 70% of client’s labor-intensive lines and processes.
The Results
7-year on-site partnership with continuous growth and margin improvement. 100% increase in output and 20% decrease in costs.
Management of Hand Packaging Departments
Case Study: Revenue Increase With Printing Company
The Challenge
Printing company was looking to offer clients hand work as part of their solution in order to offer higher value marketing and signage programs. They needed expertise in pricing and executing handwork since in-house knowledge focused on printing.
The Solution
Productiv placed a Supervisor on site and hired the printer’s existing handwork department. Productiv provides real time pricing to print estimators and manages all hand packaging projects.
The Results
Client has additional services to offer clients for incremental revenue stream. Productiv’s locked-in pricing allows client to accurately estimate and win more projects with value-add hand packaging opportunities.
Fixed-Cost Labor Programs
Case Study: Improving Quality And Throughput For Medical Device Supplier
The Challenge
Internal teams were not keeping up with hospital demand for multiple versions of medical kits.
The Solution
On-site program was implemented to improve throughput and quality. Restored warehouse inventory to optimal levels.
The Results
Using ‘The Productiv Way’, teams increased throughput 20%-50%, even for complex 65-item kits.
Rework and Product Inspection
Case Study: Using 'Sprint Capacity' To Fix A Wide-scale Issue With A Mislabeled Product
The Challenge
1.5 million lip balms from a global brand arrived from Asia mislabeled.
The Solution
Productiv teams inspected and repacked every beauty kit to be store-ready for the holiday season.
The Results
500 pallets arrived in one day and were inspected, reworked and salvaged for retail in just 22 days.