Roseville distributes repair and replacement parts worldwide-over 195 different components- for every product HP makes. For replacement printhead carriage assemblies for the company's popular DeskJet(TM) printers the Roseville facility had been using eight different packages of polyethylene foam cushions that are glued to corrugated. "And that wasn't enough" says HP packaging engineer Suzanne Keeler. "At times our material handlers were actually cutting and pasting packaging components to make products fit." The company sought a one-size-fits-all package that would cut costs reduce storage requirements and speed packaging assembly.