WorldStar Winner: EWP3 - Schaeffler - Volvo - Boxon

WINNERS 2025

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EWP3 - Schaeffler - Volvo - Boxon - packaging optimization

Company:

Schaeffler; Boxon AB

www.schaeffler.com

Country: Czech Republic and Slovakia

Category: Transit

The aim was to optimize packaging for customer Volvo. New design of adapter, insufficient quantity and quality issues lead to change of whole packaging concept. In cooperation with Volvo and Boxon supplier we redesigned an existing disposable tray and changed to cardboard separator. Key objectives included reducing of intralogistic movements, recyclability, carbon footprint, material efficiency and cost per unit.

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Increased pallet unit capacity by 100% & 166 %, now accommodating 192 / 256 parts per PU and 256 (up from 96 for both variants)
Saved 25,000 pallet positions over the project lifetime, significantly reducing storage and hadling costs
Optimized takt time in our production process
Achived CO2 savings of 1247 tons over the project lifetime
Lowered delivery costs throughtout the entire supply chain
Prevent movement inside the box, several cutouts have been added to protect sensitive parts
Implemented a cut-out for the pipe - poka yoke - avoid downtime and errors during packaging on the line
The packaging meets all legislative and customer labeling requirements and is fully recyclable

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