DeWys
Full-Service Metals Manufacturer Cuts Reject Rate in Half with Automated Wrapping Machinery
The Challenge
At DeWys Manufacturing in Marne, Michigan, COO Mark Schoenborn oversees operations for the “Circle of Companies,” a full-service metals manufacturer delivering precision sheet metal fabrication, machining, welding, powder coating, assembly, and direct shipping. With nearly 150 pallet loads shipped daily and a staff of 160, packaging and shipping were causing major headaches.
Even with DeWys’ commitment to Lean Manufacturing principles, the company still faced:
- Return rates: Scratches, scuffs, and defects during transport were leading to order rejections, costing thousands per shipment.
- Product instability: Heavy, long, or awkwardly shaped items often shifted during transit because the stretch film did not secure the load to the pallet.
- Labor-intensive: Pallets were wrapped by hand or on semi-automatic horizontal turntable wrappers, requiring two workers per pallet.
“I was growing increasingly concerned about the cost of returns and their impact on our reputation,” says Schoenborn. “Even small defects create delays and frustration for our customers.”
The TAB Wrapper Tornado Solution
Schoenborn discovered the TAB Wrapper Tornado at the FABTECH trade show. Unlike horizontal turntables, the TAB Wrapper wraps 360 degrees around and under the pallet, securing the load directly to the skid and creating a single, unitized package.
Key Technology Features
- Orbital 360° wrapping: Encases the palletized load in multiple layers of plastic film to secure products directly to the skid, preventing shifting during transport.
- High-speed operation: One operator can wrap a pallet in seconds, compared to the previous method, which required two workers and one minute per pallet.
- Versatility: Handles a wide range of product sizes, shapes, and standard 48-inch pallets with a single 80-inch model.
- Labor and cost savings: Eliminates metal banding, reduces overwrapping and manual labor steps, and decreases material waste.
- Ergonomic design and safety features: Wireless remote operation, side-loading film access, multiple emergency stops, and automatic power-off improve operator safety and reduce repetitive strain.
“I immediately saw how the TAB Wrapper fastens the load to the skid and knew it would prevent product damage during transit and make our whole system run faster and more efficiently,” says Schoenborn. “I bought one on the spot.”
Implementation and Results
The impact was immediate: pallets that previously required two workers and one minute could now be wrapped by a single operator in 15 seconds. At 150 pallets per day, this translates to two hours saved daily and 1,040 man-hours annually, equaling $15,600 in direct labor savings.
Other Results Included:
- ROI in under one year, thanks to labor and material savings.
- Eliminated manual wrapping and turntable use, simplifying the packaging process.
- Reduced return rate by at least 50%, preventing thousands of dollars in product damage and enhancing customer satisfaction.
- Maintained on-time delivery and supported growth without hiring additional staff.
“The TAB Wrapper has virtually eliminated customer complaints due to load shifting in transit,” Schoenborn notes. “It saves time, saves on labor, and we wrap everything we physically can on it. It’s definitely worth it for anybody who wants their products to arrive safely after they’re shipped out the door.”
TAB Wrapper Orbital Stretch Wrapper Solutions
If your manufacturing operation faces similar packaging problems, TAB Wrapper offers proven orbital stretch wrapper technology designed to eliminate wrapping limitations while improving safety, efficiency, and cost control.
To learn more about TAB Wrapper visit our TAB Wrapper page.
For more information on DeWys Manufacturing, call (616) 677-5281 or see www.dewysmfg.com.
