CASE STUDIES

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Client: Gerber

Background
In 1985 Gerber began a relationship with Plastic Ingenuity as their thermoforming partner.  At its peak, PI thermoformed 21 different jobs for Gerber.  After a seven year run, Gerber began running some of these jobs in-house, and in 2005 Gerber decided to terminate the partnership and return all 21 of these projects back to their own thermoforming facility. 

Objectives
Three years later, one of the thermoforming machines Gerber was using malfunctioned, leaving them with a significant shortage of parts.  If they didn’t get at least 100,000 parts within 48 hours, and 600,000 parts within 72 hours, they would have to shut down their production lines, which is a costly undertaking.  In order to avoid this, they immediately called Plastic Ingenuity to determine if we could help them with their predicament.

Solution
The call came in 1:00 pm, was returned within 30 minutes, and by 4:00 pm, two representatives from Plastic Ingenuity were in the Gerber offices in Reedsburg, WI discussing the situation   Following the meeting, The PI team returned to Cross Plains where they devised plans to re-create the necessary tools to produce the parts for Gerber within the stated time frame.

The next day the tool was completed, and by that evening, quality parts were being thermoformed.  The following morning, the first 100,000 parts were delivered to the Reedsburg facility, with the balance of the order delivered the next day.  All 600,000 parts were delivered on time, meeting and exceeding Gerbers’ timelines and expectations.
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