SEM’s existing retail display was time-consuming and labor-intensive to pack. Each display took more than 20 minutes to assemble and required 12–15
people working seven days a week to keep up with demand. Products also had to be removed from their existing trays and repacked into the display.
BCI redesigned the display around SEM’s existing product trays, making the trays part of both the pack-out process and the finished retail display. The new design eliminated unnecessary unpacking and repacking, dramatically simplifying assembly and improving overall pack-out efficiency.
The redesigned display reduced pack-out time from more than 20 minutes to just 6–7 minutes. SEM reduced its pack-out team from 12–15 people to seven and cut production from seven days a week to four — while the program generated more than $160,000 in sales in a single month.
