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Revamped packaging protects windshield shipments

American Honda saves more than $500ꯠ annually through reduced glass breakage.

The new, uniform pressure-regulated design is simpler to assemble and far more effective in preventing glass damage.
The new, uniform pressure-regulated design is simpler to assemble and far more effective in preventing glass damage.

In 2001, Dave Allison, a packaging assistant manager for American Honda Motor Co., Troy, OH, recognized a need to reduce damage rates on deliveries of windshields to AHM dealers. Improvements in shipper packaging design were crucial to solving the problem.

Enthusiastically confronting the challenge, Allison proceeded to identify the specific weaknesses in the current design and then evaluated 14 alternative glass packaging styles over an eight-month period.

Analyzing the problem

The old windshield packaging design incorporated three different sizes of corrugated boxes with multiple foam and corrugated board inserts. Triangular corrugated components were used to support the bottom of the glass, and foam slabs were used on the sides and top of the package to secure the position of the glass in the center of the pack. Any dead space at the top of the box was filled with buildups of additional corrugated board pieces.

This packaging method relied on the experience and aptitude of the pack assembly personnel to ensure that the proper box sizes and dunnage (protective packaging components such as corrugated mats and foam cushions) were used to pack each windshield size and style. Because of the variety of choices for boxes and dunnage and the varying inventory levels of these packaging materials at the pack sites, the windshield packs lacked consistency.

A close analysis of the old pack style also revealed that the interior dunnage did not properly support the glass in a vertical drop—which was responsible for an estimated 98% of windshield shipment damage. All these problems combined to result in an annual OAR (Order Adjustment Record) rate of 7.6%. OAR is the measurement AHM uses to gauge the number of orders to their dealers that must be adjusted because of underages, overages, damage, wrong parts, and so on.

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