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Easy Cost Reduction

Packaging Cost Reduction

#Manufacturing

Practice this beginner-friendly cost reduction case interview question in the Manufacturing sector. Includes detailed problem prompt, clarifying questions, structured framework, and expert recommendation. Part of ProHub's 835+ consulting case library.

ProHub Comment

This case guides candidates through structured cost reduction analysis using simple arithmetic and tradeoff thinking. The framework emphasizes brainstorming around root causes (internal processes vs. client-driven demands) before diving into supplier data, with explicit attention to non-financial risks of supplier consolidation.

Estimated Time 16 minutes
Difficulty Easy
Source Columbia
19 / 100
The client is a tier 1 supplier to the auto industry, manufacturing and distributing both electrical and seating components. The client is concerned about the high costs related to its packaging operations. Your client, the VP of Supply Chain, is targeting a 30% cost reduction of their total packaging cost in 12 months

Clarifying Information

  1. $60M is the current total spend on packaging, 1/3 on corrugated boxes, 1/4 on reusables containers, remainder on other items like palettes
  2. New ‘diversity’ supplier of corrugated cardboard has a pricing proposal: (i) 4M boxes at $4.50/box; (ii) 5.5M boxes at $3.00/box; (iii) 7M boxes at $2.50/box
  3. 2% federal rebate on purchases from ‘diversity’ suppliers
  4. Client currently pays $4 per box and $200 per container. Each container is equivalent to 10 boxes. Client is only exploring a deal with this potential supplier
Mock Interview
Interviewer

The client is a tier 1 supplier to the auto industry, manufacturing and distributing both electrical and seating components. The client is concerned about the high costs related to its packaging operations. Your client, the VP of Supply Chain, is targeting a 30% cost reduction of their total packaging cost in 12 months

You

Thanks. Before analyzing, I'd like to clarify a few key questions...

Interviewer

Good question. Let me provide some background information...

You

Based on this, I suggest analyzing from these dimensions...

AI Score
Structure Analysis Communication Business Sense Quantitative
Practicing...
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Practice this case with AI Mock Interview

A tier 1 auto supplier seeks a 30% reduction in $60M packaging costs. Through structured analysis of corrugated boxes vs. reusable containers and evaluation of a new diversity supplier’s pricing tiers, the recommended solution achieves a 30.1% cost reduction by eliminating reusable packaging and consolidating corrugated box purchases, while acknowledging implementation, quality, and relationship risks.

Key Insights:

  1. Cost reduction requires examining both internal process inefficiencies (supplier fragmentation, lack of coordination) and business model tradeoffs (disposable vs. reusable packaging economics)
  2. Switching to a single new supplier achieves the numeric goal but introduces concentrated risk in quality, capability, and relationship flexibility that must be explicitly managed
  3. Supplier consolidation can deliver savings but requires careful stakeholder engagement, clear communication of requirements, and understanding of operational impacts before implementation

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