56% drop in windshield damage for a North American automotive manufacturer
10th March 2026 | 2 min read
The Challenge
A major automotive manufacturer was experiencing high levels of windshield damage across North America. Many shipments from its East Coast distribution centre travelled up to 3,000 miles, and the packaging in use was not suitable for carrier handling.
This led to costly damage claims, $65K from January to August 2024, with overall damage costs remaining high despite a downward trend. Retailers were also affected, having to reorder the same windshields multiple times to complete vehicle repairs, causing frustration and operational inefficiencies.
Unipart was brought in to reduce damage, improve shipping processes, and help the manufacturer provide a more reliable and cost-effective service to its retailers.
The Solution
Unipart collaborated with the manufacturer to deliver a comprehensive solution combining operational improvements with innovative packaging.
The approach included:
- Warehouse storage improvements: Adjusted storage practices to reduce in-house damage.
- Inbound inspection: Introduced a more thorough process to catch concealed damage before shipment.
- Bespoke packaging: Engaged a packaging specialist to design a solution suitable for all North American warehouses.
- Trial and testing: Piloted multiple packaging variations, including drop tests and limited retailer shipments, to identify the most effective and cost-efficient solution.
- Carrier collaboration: Worked with carriers to improve handling practices and introduced shock tags.
- Referral order reduction: Limited windshield referral orders to reduce long-distance transport and the risk of damage.
- Active customer collaboration: Manufacturer representatives worked on site with Unipart staff and the packaging engineer to ensure the solution met operational and cost requirements.
The project faced several challenges along the way. Early packaging designs didn’t fully prevent damage, so the team went through multiple iterations to strike the right balance between protection and cost. Transporting delicate windshields added another layer of complexity, as carrier networks weren’t built for fragile items. To mitigate risk, long-distance shipments were limited and referral orders carefully managed.
Space constraints ruled out the use of roll cages, prompting the team to develop a solution that safeguarded both individual windshields and bulk shipments. Through thorough testing, close collaboration, and creative problem-solving, these obstacles were overcome. The final solution was successfully rolled out across all North American distribution centres (Unipart & Neovia), delivering a robust, cost-efficient approach that reduced damage and improved service reliability.
The Impact
Damage claims dropped by 56%, cutting overall costs by 48% and reducing the need for repeat orders. Retailers experienced a more reliable service, while the manufacturer benefited from smoother, more efficient operations across the North American network. By combining innovative packaging with operational improvements and close collaboration, the project delivered immediate savings and strengthened the manufacturer’s ability to protect high-value parts in transit.