When parts leave a facility undamaged but arrive at their destination in disrepair, one of the first suspects is the packaging. And no one knows that better than Schefenacker Vision Systems USA Inc.

The automotive mirror manufacturer had been shipping its interior and exterior car mirrors to major auto plants in good condition. But they were arriving in scuffed and crushed boxes, and less than perfect condition. That led Schefenacker to replace its disposable packaging with reusable totes that better protect the mirrors.

But the company didn't stop there. It was also receiving damaged goods in disposable packaging from its suppliers. As a result, Schefenacker strongly encourages its suppliers to switch to reusable totes too.

"We are now seeing 50% of our suppliers using returnables," says Lynn Krohn, Schefenacker packaging engineer.

Schefenacker's 225,000 square foot facility in Marysville, Mich. feels the positive impact of durable packaging. Its plastic returnable totes practically eliminated damage to its shipments. The totes also cut the company's packaging costs by 90% in the first year.