Egg-Crate Trays Ended a Tangling Problem Without Changing the Part

A regulator maker's stamped clips shipped in gridded trays, three per cell. In transit the clips shifted, nested, and tangled; operators picked up two or three at a time, bent a few prying them apart, and assembly slowed on a part that should have been invisible.

We fixed the tray, not the clip. Each clip now sits alone on a paperboard spindle in an egg-crate tray; trays stack without compressing the lower layer. Fewer clips per tray than before — but the spindles take vertical load off the parts, so more trays fit in the same master carton, and net parts per carton actually rose.

Outcome

• 77 clips per tray, tangling and transit damage eliminated
• More pieces per master carton than the old high-density tray
• The customer's pack-out station loads faster — regularly spaced spindles, no counting
• Assembly-side bent-part rework stopped at the line

Specifications

reel, spindle tray, or bulk packing per your line · packaging design included in DFM at no charge · MOQ 10,000