United States – October 29, 2026 -- SupplyOne cut the average pack size by more than 20% for a nationwide distributor of new OEM automotive parts, lowering the customer's dimensional-weight shipping costs.
Manual RSC box assembly could not keep pace with order growth
The distributor runs strategically located distribution centers and more than 250 retail locations. As order volume grew, it needed to move beyond manually assembled RSC boxes. The new process had to support both retail distribution and online fulfillment.
Rightsized carton equipment forms trays at each packing station
SupplyOne built the program around speed, consistency, branding and freight efficiency. Its automated pack-out equipment forms right-sized trays automatically at each packing station, which reduces manual box setup.
SupplyOne also developed large and small corrugated trays with custom printed lids. Online orders carry their own branded graphics.
Managed VMI/RSA program supplies corrugated, labels and hot-melt adhesive
An integrated consumables program supports the operation. SupplyOne supplies corrugated, labels and hot-melt adhesive through a managed VMI/RSA arrangement.
The 20%-plus reduction in average pack size is the only quantified result in the case study. The source gives no throughput figures, though SupplyOne describes the throughput gain as significant.