Tempur Sealy Reduces Returns by Over 90% With New Box Design
Tempur Sealy Reduces Returns by Over 90% With New Box Design
2 PagesTempur Sealy Reduces Returns by Over 90% With New Box Design Brandon Freeman Executive Summary Tempur Sealy International tasked FlexPAC with creating a new, corrugated box design for their queen size mattresses. Prior to FlexPAC’s design, Tempur Sealy used a two-piece box that ?t together on the assembly line to house their mattresses. Within the shipping process, the boxes often were damaged or ripped causing the mattress to be dirty when it arrived at the customer. Returns were common, assembly time was high, and the material cost to put the box together was large. FlexPAC’s newly created, single-piece box design helped eliminate unnecessary packaging materials, protect their shipments to customers, and dropped their return rate by over 90%. Challenges On the assembly line, the mattress
