For over a few decades Garthwest has been the POS designer, manufacturer, distributor and co-packer for a number of large film distributors. One of our largest customers being UCA, an alliance consisting of some of the biggest movie studios in the industry, from Universal Studios to Sony Pictures Home Entertainment. UCA was looking to reduce their cost significantly per unit for a DVD FSDU (Free Standing Display Unit). Consequently, we were asked to suggest design changes for the company’s fastest running unit so that they could reduce their material cost.
Our customer had large multiple POS item campaigns going out to multiple stores in the Mainland UK, Highlands and Islands. Quantities varied from a few hundred to a few thousand POS items at a time, each with bespoke artwork arrangements.
The Brief
Our brief was to reduce material cost, but at Garthwest we like to take an holistic approach to any brief and included additional steps to ensure the best outcome possible.
After the briefing and an initial ideas session it was decided to pursue the following goals:
- Reduce the amount of material – to reduce overall cost, our customer’s main requirement
- Simplify manufacturing – pass any reduction in cost direct to our customer
- Simplify artwork layouts – give the customer a saving in staff resource and improve turnaround
Co-Op Most Wanted Gifts – 20 Facing 3 Deep DVD FSDU
The project
Firstly, a workflow was designed which meant the artwork and design processes were streamlined efficiently between our two companies. This massively improved lead times by removing previous funnels that were causing delays within the process.
Secondly, utilising our in house design team, we suggested a few different viable design options from which the customer could choose. This ensured there was no negative impact from the designs we were considering and to ensure the customer was completely satisfied.
Fast & Furious 8 – 8 Facing 3 Deep DVD FSDU
The outcome
The final unit achieved a 50% reduction on all materials and therefore reduced the overall cost. The unit was also much more efficient than their previous one, making it easier for store staff to assemble.
By using intelligent palletisation software, we also increased the amount of merchandised units, meaning we were able to fit three times as many of our new units on a pallet than the previous design.
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