Automotive manufacturer reduces trim part damage by 57%

Automotive manufacturer reduces trim part damage by 57%

17th November 2025 | 2 min read

The Challenge

Since 2017, Unipart has partnered with a leading automotive manufacturer in North America, operating multiple warehouses across the region. In 2022, the partnership was renewed for another five years, reflecting exceptional performance at the sites. In recent years, this collaboration has evolved into close alignment on best practices and continuous improvement.

Amid this strong performance, the manufacturer’s North America warehouse network faced a persistent issue: a high rate of damage to trim parts, the most frequently damaged products. This led to more claims, retailer complaints, and delays in customer repairs when parts had to be resent. Reducing these incidents was essential to improving service levels and minimising operational disruption.

Best practice sessions with the manufacturer’s logistics partners, including Unipart, revealed a notable difference: some warehouses in the network experienced far fewer damage issues. Investigation showed that packaging design, particularly box size and shape, was a key factor. This insight shaped the solution implemented at one of Unipart’s North America warehouses.

The Solution

The warehouse conducted a thorough review of handling processes to identify when and where damage was occurring, aiming to reduce risks throughout the entire supply chain, from receipt through storage, picking, and shipping.

Based on successful trials at another site in the network, tubular bin boxes were introduced for trim storage to protect parts from bending or crushing. To further reduce damage risk, all trim was removed from high storage and made pedestrian pick only, minimising potential harm from forklifts or automated equipment.

Working closely with the corrugated packaging provider, Unipart designed a new shipping box specifically tailored to better protect trim parts during transit. This design was approved for use across the North American network.

In addition, bespoke picking carts were developed and carpeted, with specialised compartments to stabilise long, delicate trim components during picking. These carts reduced the likelihood of damage during internal handling, enhancing the protection already provided by improved storage and packaging.

The Impact

The combined efforts of the project resulted in a 57% reduction in trim-related damage claims across the manufacturer’s North American warehouses, significantly decreasing retailer complaints and repair delays. Additionally, the bespoke picking carts will help reduce inadvertent damage to other parts during picking. These improvements boosted product quality and reliability, enhancing the overall customer experience.

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