The ChallengeAfter meeting Debenhams, a keen interest was shown in our stock range of boxes, in particular the crashlock Crashlock. Debenhams were looking for a solution to packing time inefficiency. They were operating their fulfilment from the basement of the Southampton store and were very restricted for space.
- Debenhams online sales of health and beauty products had doubled over recent years in a fulfilment warehouse that had been at full capacity for some time. The choices were to move premises, something that would be a very costly exercise or double the fulfilment speed to allow for the 100% growth forecast. Adding more staff to the operation was not an option as they were already at the limit of their packing desk capacity. In short, they needed the current staff to pack items quicker.
- A highly secure packaging solution was needed, as the protection of the contents was paramount.
- The current herring bone perforation was failing trials, an alternative was needed.
- Debenhams needed quality packaging that reflected their great brand image.
- During our search for an efficiency solution for Debenhams we carried out a trial which was split into two separate processes:
- Reduction of the time taken to construct the box. The 0201 current standard box used by Debenhams took 12 minutes 45 seconds to construct 50 cartons as compared to the Lil Packaging Crashlock which took 5 minutes 24 seconds to construct the same number of cartons.
- Reduction of the time taken to pack and seal the unit ready for despatch. The analytical technology at Debenhams allowed us to monitor how many items were despatched per hour by the same packer using their current box as compared to the Lil Packaging Crashlock. The amount of units despatched over a 1 hour period of the current Debenhams box was 73 units. When the same test was carried out with the Lil Packaging alternative, including peel and seal, 157 units were despatched within an hour.
- The hot-melt peel and seal closure system used by Lil Packaging was found to be superior to competitors options with at least twice the strength of standard double-sided tape. This provides significant confidence when sealing the packaging.
- Lil Packaging worked with the design team at Debenhams to remove the external artwork on the packaging, therefore increasing the security of the contents. Flood coat printing was used on the inside of the packaging instead, maintaining the Debenhams brand and improving the customer experience on opening the goods.
Debenhams changed all of their 0201 boxes to the Lil Packaging peel and seal crashlock box - the Crashlock. Debenhams were able to save money by reducing the number of packing staff, and manual packing facilities such as tape guns and desks. With the ability to dispatch almost twice the amount of orders each day, Debenhams were able to remain at their Southampton premises for another year.