Reusable Packaging is the Game Changer in the Automotive Industry

Never before has it been more crucial for automotive enterprises to review their packaging needs. Packaging is the one key element that is often overlooked when designing and investing in a new line of vehicle manufacture or moving parts in a closed loop system for processing. When packaging is viewed as an integral component of the manufacturing process, it results in significant improvements to cost and time savings.

Primarily we look at the deep technical design characteristics of parts and the resources required to manufacture and provide defect-free products. Yet we simply discard our single-use packaging into a boldly marked waste bin as “WASTE PAPER” and money is lost.

KAYMAC has developed an innovative system using heavy-duty reusable, collapsible bins that are structurally-foamed to endure the conditions of everyday use in the most demanding and toughest manufacturing operations. KAYMAC collapsible bins (referred to as KAYMACs) are manufactured with original tooling designed for the North American automotive market, manufactured in South Africa to exact standards. Designed to fold down, thereby reducing space when not in use, they are easily built up by unfolding each panel to lock into each other, thus forming a solid robust container ready for immediate use.

The bins’ panels are hinged on multiple pivot points ensuring that the integrity of the bins is not compromised and therefore delivering many years of service. A patented locking system is incorporated into the design: when the bins are assembled, the design ensures that the panels are snap-locked into position until the bins are ready to be folded down and stored away. Lids are available in heavy-duty and light-duty options; the former being ideal for demanding applications, and the latter serving the purpose of a dust cover within internal manufacturing operations in a closed loop system.

In recent years various cost driven strategies by the automotive and first tier manufacturers have seen a migration from hiring reusable packaging to the outright purchase of reusable packaging. This strategy was first adopted by one of the world’s leading Japanese automotive manufacturers and its first tier supply base located in Durban. Thousands of collapsible bins were purchased for the first project in 2007. The results and cost-savings proved so successful there was no hesitation in specifying the same bins for the next project as the “KAYMACs outperformed and exceeded all expectations”. This new project pushed boundaries when the specifications changed to the EURO footprint – 800 x 1200 – a game changer in localised packaging. KAYMAC rose to the challenge and supplied collapsible bins to this specification, thereby creating a new range of collapsible bins, which is fast becoming an industry standard.

Consequently, when one of the world’s leading German automotive manufacturers opted to build a model for worldwide supply at its Rosslyn plant, KAYMAC collapsible bins were the number one choice. Manufacturing and supplying to very tight deadlines, from initial samples for line side trials to full scale production and volume ramp-up, KAYMAC delivered on schedule - another success story.

Fundamentally  all investments must add value to a business, especially in the manufacturing environment. We design, develop and test dunnage to protect parts as they travel from various locations around South Africa to the assembly lines of the manufacturers.
The smart designing of dunnage to hold parts in layers within the collapsible bin provides the end user with the opportunity to pack more parts into a bin. The bin packed with parts takes up less  space on the production line and valuable production space can then be utilised for manufacturing.
Additional advantages of KAYMAC Bins:

• Serviceable – damaged or worn parts can be easily replaced
• Recyclable - when it eventually comes to end of its life cycle
• Flexibility  – adapting to many industries from healthcare to foundries and everything in between
• Durability – correctly maintained and managed, provides years of service, saving money
• If you want to learn more about our collapsible bins go to www.kayroto.co.za and let us help you with your next project.