Brand Loyalty – What Is The Cost Of Disappointment?

You know how if feels, last minute purchasing, ordering the product too late, rushed delivery, hurry to the store – all to receive a less than attractive product package.  Maybe the package is dented, torn or crushed; or it could have been previously opened or it is missing critical components.  Maybe you are a manufacturer waiting for inputs to your process and half of the product is lying on the floor of the truck.  This is disappointment.  Disappointing experiences are remembered, repeated and attached to our brands.

To those of us familiar with the concept of brand loyalty, we understand that when brand loyalty is damaged, there are consequences.  Yet, the concept and its ramifications seem to be intangible, emotional and difficult to express in mathematical terms.  When this is the case, it becomes challenging to create a business case for investing and improving processes that directly influence brand loyalty.

Interestingly, I recently came across a study on consumer behavior when presented with damaged packaging.  The information I found most fascinating include:

  • Perception of a product as a “brand you trust” dropped from 73% to 41% when packages were even slightly damaged
  • 25% of the most brand-loyal shoppers question the safety of the product when the package is damaged
  • Up to 55% of shoppers discarded the brand, and 36% opted to purchase another brand

These numbers presented are eye opening, but what, then is the financial impact of these data? Taking the information in the study, we applied a hypothetical percentage of damaged packaging into the model and based on the following assumptions, we arrive at the model below.

Sales price = $5
Percent of users switching brands = 36%
Annual Revenue = one $100,000 project per month

Revenue Quantity Percent Damaged Product Packaging QTY Damaged Return Cost Customers Lost Due to Brand Switch Revenue Lost Due to Brand Switch Annual Revenue Lost Due to Brand Switch
$100,000 20,000 1% 200 $1,000.00 72 $360.00 $4,320.00
$100,000 20,000 2% 400 $2,000.00 144 $720.00 $8,640.00
$100,000 20,000 3% 600 $3,000.00 216 $1,080.00 $12,960.00
$100,000 20,000 4% 800 $4,000.00 288 $1,440.00 $17,280.00
$100,000 20,000 5% 1,000 $5,000.00 360 $1,800.00 $21,600.00
$100,000 20,000 10% 2,000 $10,000.00 720 $3,600.00 $43,200.00

 

Reviewing this model, I notice at the 1% defect rate, my damage is only costing $4,320 per year.  While the observation is correct from a GAAP accounting perspective, it does not take into account the costs to acquire new customers, the lifetime value of customers, and attrition rates.  Additionally, the perspective does not count the number of people with whom the 72 lost customers discuss their disappointment.

For More Information

Check out this video to learn more
about how to prevent product damage within the supply chain.

Click Here to learn more about how
ASAP can help you with your damaged product issues.

So, what is the total cost of disappointment?  It seems to me, the answer lies more in our approach to the question, than the articulated dollar amount.  When we engage in a process that allows us to explore different perspectives including, sales and marketing data, operational data and the experiences our customers are having, we might then obtain an accurate account of the cost of disappointment.

Reducing Variations In Assembly And Packaging Processes – A 3-Step Guide

Assembly and packaging processes, sometimes referred to as secondary processes, can be difficult to define, measure, analyze and control. Labor-intensive, secondary processes performed by us humans seem to present the most challenges. The unpredictable nature of human performance can be overwhelming, making it seem impossible to feel confident about the accuracy and consistency of our processing methods.

Uncertainty feels risky and is frustrating to deal with. Blaming the people performing the process seems like an appropriate behavior, however, I have found it is more productive to take a curious approach and understand what drives this unpredictability.

So the then the question becomes how. What course of action can be taken to understand what causes variation and unpredictable outcomes? Broadly speaking, we need to look at the system inputs, such as, process, people and tools. The first input to become curious about is the process. Some questions to consider include:

  • Is the process defined?
  • Are process tasks defined?
  • Are tasks and sub-process measurable in terms of quality and quantity?

Once the process is defined and measurable, move to a review of the tools needed to perform the tasks and sub-processes. Some questions to consider about tools include:

  • Are the tools widely available
  • What training is available for tool use
  • How are tools calibrated and maintained to ensure consistent performance.

Finally, we can review what specific skill sets are needed to use the tools and perform processes. Some questions to ask about skill sets include:

  • What types of motor skills are needed, fine, gross or a combination of both?
  • Are hand strength and dexterity needed?
  • Are detailed math skills needed for measuring and counting?

After negotiating this adventure in curiosity, we can start inserting humans into a well designed, measurable process where variations can be analyzed and controlled.

While this 3-step guide may seem time consuming, the benefit of doing this work is an ability to create fantastic training programs to further our goal to offer great products to our customers.

Speaking of great training programs, check out this sample video, highlighting ASAP’s performance training video production capabilities.  We have also included the corresponding Shrink Wrap Quality Training Test.

Damaged Product – A 6-Step Process to Resolution

Damaged product is simply not acceptable. Whether our products are OEM or retail, customer interaction with product packaging and the product is critical. Retail customers, like you and me, do not buy products that have dents, broken shrink-wrap, or torn labels. Likewise, OEM customers do not want to deal with fallen over pallets, banged-up outer cartons or ripped open bags. This kind of damage greatly reduces an OEM’s ability to be efficient and creates questions about the quality of the goods received.

Damaged product packaging and products has negative consequences, both from a brand loyalty perspective and from an internal costing perspective. The cost associated with brand loyalty is decreased revenue opportunity. Often customers do not tell us their problems; they simply quit buying our products. The internal product costs are bit easier to determine through cost modeling. With consequences such as these, it leads us to wonder how product packaging and product damage occurs and how can these issues get resolved?

For More Information

Check out this video to learn more
about how to prevent product damage within the supply chain.

Click Here to learn more about how
ASAP can help you with your
damaged product issues.

The following is a comprehensive process to resolve damaged product.

1.  Document the actual damage that is occurring through samples and photos.

2.  Evaluate the frequency, assign costs and create cost model to understand the financial impact and establish a budget for improvements.

3.  Map distribution channel, noting the various conditions the product experiences as it travels to the end-user.

4.  Examine manufacturing systems to insure products are safely transitioned from operation to operation.

5.  Examine the packaging system including:

    • Primary packaging practices
    • Secondary packaging practices
    • Tertiary packaging practices
    • Pallet patterns
    • Pallet protection materials

6.  Document findings and create an action plan incorporating root cause and budgetary factors.

Naturally, executing and earning the ROI on this 6-step process takes deep commitment from corporate leadership and cross-functional staff members alike. However, embracing a curious approach to problem solving and establishing budgets can make all the difference in resolving issues surrounding damaged product.

Bulk Pack For Huge Savings in Display Fulfillment & Kitting Costs

Display fulfillment and kitting projects often require products packaged in their primary package, to be placed into an assembled display.  Likewise, kitting projects require packaged products to be combined and placed into a shipper carton.  Both processes require removing product from a container, typically a master carton.

Surprisingly, the quantity of product packed into this container/master carton has a big impact on the cost of fulfillment and kitting projects.  Consider that opening a master carton, removing product and breaking down the carton for recycling takes about 36 seconds.

While at first glance 36 seconds seems inconsequential, this is where the carton quantity has an impact.  Since it takes 36 seconds to open, remove and discard a master carton, these seconds become fixed.  Whether we are removing 3, 12 or 25 parts from a carton, it still takes at least 36 seconds to perform the product removal process.

Working with the assumption that 36 seconds is a fixed process time, the method to determine the product cost is to distribute process time evenly over the carton quantity. For example, if the carton quantity is 3, then divide 36 seconds by 3 parts equaling 12 seconds per product.

Carton Quantity

3

12

25

50

Removal Process Time Per Product (sec)

12

3

1.44

.72

Next, multiply the seconds per product times a fully burdened labor rate.  For example, 12 seconds times a $30/hr equals $.099 per product.  Therefore, the cost for simply removing one part/product from its secondary packaging is about $.10 per part.

Carton Quantity

3

12

25

50

Removal Process Time Per Product (sec)

12

3

1.44

.72

Cost per Product – $30/Hr Labor Rate   ($) $.10 $.025 $.012 $.006

Now, if the a finished display requires 50 parts per display, then the cost per display for simply removing the product from its carton is $5.  This chart below illustrates the impact carton quantities have on display fulfillment costs.

Carton Quantity

3

12

25

50

Removal Process Time Per Product (sec)

12

3

1.44

.72

Cost per Product – $30/Hr Labor Rate   ($)

$.10

$.025

$.012

$.006

Cost per Display – 50 Parts/Display ($)

$5

$1.25

$.60

$.30

To determine the cost per display project, multiply the order quantity 500 times the cost per display.  For example, 500 times $5 equals $2,500. The chart below illustrates the removal cost based on order quantity and the potential saving of bulk packing product for display projects.

Carton Quantity

3

25

Cost per Display – 50 pieces per Display

$5.00

$0.60

Cost per display order – 500

$2,500

$300

Cost Saving For 25 Carton Quantity

$2,200

 

Furthermore, bulk packing products that are going into display projects, reduces the amount of cartons needed, which reduces secondary packaging costs while reducing waste and garbage removal costs.  The chart below demonstrates the opportunity for material and waste reduction.

Carton Quantity

3

25

Product needed to fulfill display 50*500

25,000

25,000

Cartons per pack-out quantity

8,334

1,000

Material Saving For 25 Carton Quantity

7,334

 

Obviously, there are additional steps to a fulfillment process than simply opening, removing and discarding the secondary packaging of a product.  However, a simple change in secondary packaging quantities has the potential for huge labor, and material cost savings.

Complete Brand Packaging Begins With The End In Mind

A lot of time and resources are spent on branding efforts.  Brand recognition and brand loyalty are considered assets and are tracked and measured. We chose images; colors, shapes and text that we believe will help communicate the kind of experience our target market is going to have when they purchase our products.  In short, we are making promising to our customers and working to earn their trust.

Earning trust is a difficult task and once we entice a customer to buy, delivering on our promises becomes critical.  One strategy to build customer confidence is to incorporate marketing messages into product packaging.  Most purchasing decisions are made in store and the package presentation is the first concrete opportunity to continue delivering on brand experience promises.

For More Information

Check out this video to learn more
about how to prevent product damage within the supply chain.

Click Here to learn more about how
ASAP can help you with your
damaged product issues.

After a purchase is made the product goes home with our buyer.  The next interactions include, opening the outer package, looking at and unpacking the accessories, making sure all components are included, assembling/hooking up/setting up the product and reading the directions.  Each of these interactions is communicating messages about our brand.  The more complicated and difficult these steps are, the less loyal we tend to be about the brand we just purchased.

When considering the brand experience we would like our buyers to have, it is important to think about how the package influences brand perceptions.  Some points to keep in mind when thinking about complete brand packaging include:

  • Product presentation – what is the initial impression at point of purchase
  • Production protection – what level of tamper resistance is needed
  • Product placement – how will the product be placed for purchase
  • Ease of use – the ease of opening, accessory layout and instructions
  • Product enhancement – how can the package facilitate the use of the product

It is important to consider how end users will interact with our products. The way in which the product is packaged can be a useful tool to communicate brand strategies.

Product Packaging: What Is The Impact Of Design For Manufacturability?

DesignWhen designing for manufacturability one of the perceived downfalls is an increase in the cost of materials required for the design.  Consider a master carton.  Various designs of a master carton with similar dimensions, flute, and paperweight specifications have separate manufacturing costs.  One design may require more board and another may require a more complicated die cut. Often design is viewed from a minimization of board and die cutting, leading to a cost only perspective.

However, designing from a cost only perspective can present down-stream manufacturing problems including:

  • Product protection
  • Transportation costs
  • Extra handling

These manufacturing issues can actually increase product costs resulting from product damage, increased transportation costs and increased labor costs.  Imagine if the design required an increase in material cost, but decreased extra handling.

Design Option
Material Cost
Labor Cost
Total Cost
Low Cost Perspective
$4
$12
$16
Design for Manufacturability
$5
$9
$14

On the surface these numbers look inconsequential.  However, this graph below illustrates the saving achieved when designing your packaging for manufacturability.

Designing product packaging is not always easy.  Time horizons continue shrinking as the push for lead-time reduction and quick product launches is ever present in today’s dynamic economy.  However, the opportunity for return on investment makes it clear that manufacturability is a concept that must be incorporated into our design processes.

Do What You Love, Love What You Do

“A customer is the most important visitor on our premise. He is not dependent on us. We are dependent on him. He is not an interruption in our work. He is the purpose of it. We are not doing him a favor by serving him. He is doing us a favor by giving us an opportunity to do so.”
- Mahatma Gandhi

We love our work and therefore love our clients. Really, it is true. Our enjoyment begins with our clients. You, entrusting us with an opportunity to learn the intricacies or your unique products, gives us the opportunity to provide great product packaging.

For me, the discovery process is what I love best about our work. Offering custom packaging solutions is a journey into the unknown, like the unraveling of a mystery. Many questions lead down a winding path.

  • What are the unique attributes
  • What are the priorities
  • What are the complexities
  • How do we simplify
  • What packaging process works best for the situation
  • What materials work best
  • What design works best
  • What is the most efficient supply chain path
  • How do we reduce redundancies
  • How do we reduce quality errors
  • How do we reduce lead times
  • How do we create seamless value to the end user

The discovery process is where we earn trust and get to learn about our clients’ needs. This is what I enjoy most about my work.

What do you love about your work?

Damaged Product? Modifying Your Pallet Pattern May Be The Solution

We all have experienced frustrating situations where our product has been damaged while traversing the supply chain. Often our first instinct is to look at the package design for a solution.  While that may help, the solution may lie in simply reconfiguring your pallet pattern.

We have produced a new video that explores how pallet patterns can be modified to eliminate product damage.

To view in a higher resolution, Click Here to watch on YouTube.

Trust, But Validate All Product Packaging Components

Validating all product packaging material is a critical step to ensure our product launches occur on time and within budget. Imagine, successfully navigating a very long and rigorous new product launch process only to discover, the launch is delayed by several weeks simply because the packaging material, such as a master carton, was not validated.

Something as seemingly simple as the correct sized master carton can have a major impact on meeting launch dates and anticipated profit margins. For example, a carton purchased that is too small for the product leaves us with a few options.

  1. Find an online resource that specializes in, in stock, off the shelf cartons and purchase the closest match to the dimensions and weight restrictions of the product. If necessary buy a larger box than required and fill the void with packing paper, print and apply carton labels, getting the product to market a few days later than planned.
  2. Change the carton drawing with the corrugate supplier, augment the printing and cutting die, and wait another 2 weeks to receive cartons, launching the product at least 2 weeks later than planned.

The first option gets the product to market sooner, but has several extra costs involved, affecting targeted profit margins. The second option can delay the launch by 2 to 4 weeks, depending on supplier lead times and our own product processing times and manufacturing schedules.

With both options, there are extra costs involved, including:

  • the extra cost per carton
  • the cost to return, destroy or inventory the wrong sized carton
  • the cost to augment or produce a new cutting and printing die
  • the cost to order the correct carton
  • the cost to print and apply a carton label
  • the cost to purchase and insert packing paper

To avoid these and other more, intangible costs validate all product packaging material before purchasing and launching new products.

 

Picking The Right Carton For Product Packaging

Often in product design, the focus of the design team is on the actual product and its primary packaging.  Although the shipper carton has the important function of making sure the product makes it in perfect condition through the distribution channel, the design of this package can become a rushed afterthought when entering into the launch phase.

Choosing a carton that maximizes your product’s protection without paying extra for an over-specified solution requires that you understand corrugated box construction.  The first place to find out how the carton was designed is to understand the Box Certificate that is printed on most cartons.

 

Bursting Test – This measurement is an indication of the quality of the box.  This number is determined from the Mullen test, which measures the pressure (pounds per square inch) required for the corrugate to rupture.  This measurement is a good indication of how effective the carton will be at maintaining its structural integrity when dropped or loaded with heavy contents that exert pressure on a small area of the carton.  Certification with this test requires the corrugate to be constructed within specific parameters.

Edge Crush Test – This is a new standard that is sometimes used in place of the Bursting Test.  This measurement indicates the stacking strength of the carton by measuring the minimum pounds per linear inch needed to compress the edge of the corrugate board. This method of measurement allows manufacturers to use less expensive, lighter weight board than what is required for a Burst Test certified carton.

Minimum Combined Weight On Facings – This measurement is an indication of the stacking strength of the carton certified with the Burst Test.  This number is the weight the sides of the carton can hold up when a load is applied to the top.  This measurement is generally indicated in pounds per square foot.

Size Limit – This number indicates the maximum carton size allowed for the corrugate board used to construct the box.  This is determined my adding the length, width and height of the carton.

Gross Weight Limit – This value indicates the maximum weight that can be loaded into the carton.  Although this is the specified maximum weight, consideration should be given to the type of product loaded into the box and the mode of transportation to determine what weight should actually be loaded into the carton.  A carton loaded to the weight limit with an irregularly shaped item may not be adequately protected.  Also, a carton at the weight limit may be adequately protected when palletized but prove inadequate when shipped as an individual parcel.

The goal of protective packaging is to get your product through the distribution channel and into the end user’s hands in pristine condition. Understanding the Box Certificate is a great starting point to knowing if your carton will be adequate to achieve this goal, and put you on your way to achieving your larger goal of bringing your product successfully to market.

Box Maker’s Certificate
All About Boxes
Technical Notes On The Use Of Corrugated Paperboard Boxes
Box Manufacturer’s Certificates
Understanding the Box Maker’s Certificate

 

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