Case Studies

Kitting & Hand Assembly

Converting components into goods at a fixed unit price

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.

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Packaging

Inserting, folding, finishing, wrapping, heat shrinking and more – all done with a quality guarantee

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.

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Point of Purchase (POP) Displays

Building and packing sales displays that are ready for the retail floor

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%.

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Custom Fulfillment

Managing order fulfillment, value-add services, distribution and reverse logistics for B2B and direct-to-consumer clients

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.

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4PL and Turnkey Services

Providing end-to-end services that result in supply chain velocity

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.

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Fill Lines

Operating liquid and dry-goods lines with pack out services

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.

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Management of Hand Packaging Departments

Staffing lines with managers who are trained on lean principles and best practices in warehousing, material handling, assembly, packaging and quality assurance

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.

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Fixed-Cost Labor Programs

Designing projects that prioritize outcomes instead of duration-based temporary staffing

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.

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Rework and Product Inspection

Repurposing SKUs or correcting improperly packaged/labeled goods to meet updated specifications

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.

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