Borg Warner's automotive parts plant in Muncie, Ind. regularly received shipments of components in wire containers from a Canadian supplier. Unfortunately, damage to the parts was high and the number of cases packed in each container limited to just 24. In addition, the non-collapsible containers required just as much space on over-the-road trucks to return to Canada empty as they did when full.

All that changed when Borg Warner switched to collapsible, solid-wall plastic containers that measure 48 × 45 × 38 inches.

Manufacturing engineer Anne Harrington says that the new containers accommodate more parts. "Switching containers improved space efficiency 150%," says Harrington. "With more parts in each container, we reduced trips from our supplier significantly."

Borg Warner estimates that it will save about $70,000 each year in shipping costs. In addition, the collapsible containers conserve space on their return trip. The plastic containers also protect the components better, reducing damage levels.

A drop-down door on each container improves access to the parts by workers, especially for those parts packed at or near the bottom of the container. Plant safety has improved, as components no longer protrude through the containers as they did in wire ones.

The switch to new containers has also increased handling efficiency, as operators no longer need forklifts to move filled containers. Every eight minutes, an operator was forced to stop current activity and relocate the components in the assembly area, causing constant handling headaches. Now forklifts remain on their current tasks, and pallet jacks are used to transport the new containers.