RELY · Case Study · On-site kitting and packagingMANAGED ON-SITE PRODUCTION
ON-SITE KITTING & PACKAGING · TWO SHIFTS · CONSUMER FOOD-STORAGE SETS
Delays squeezed the window. Two shifts held the retail dates.
Upstream delays compressed the schedule, then a labeling requirement was added mid-run. RELY ran and supervised on-site kitting across two shifts, built the new label into production, and held the delivery timeline.
View the original PDF- 132,115Kits assembled on-site
- 7,040Kits in one day, across two shifts
- 1,056,920Bowls and lids8 per kit
- HeldDelivery timelineAfter a label was added mid-run
The window shrank. The requirements kept moving.
A Wisconsin injection molder needed four-bowl, four-lid food-storage kits packed inside its own facility for a consumer brand's retail program. Upstream delays used most of the schedule before full-rate kitting.
HOW RELY HELD THE DATES
- 01
Stopped and started
Paused and restarted on the customer's schedule as components arrived.
- 02
Added the label
Walked placement and labor first, then built the audit label into the running line.
- 03
Validated, then restarted
A 1,120-kit labeled run passed audit before full-rate restart.
- 04
Ran two shifts
Added a 2nd shift with its own RELY lead when the window compressed.
The requirements moved. RELY moved with them.
MANAGED WORK, NOT ADDED HEADCOUNT
- Supervision on both shiftsA RELY lead on each shift, with a RELY production manager supporting execution.
- The kit itselfFour bowls and four matching lids per carton, then downstream packaging.
- Validation and restartValidation runs into production, including the audited labeled restart.
- Two-shift output44,135 kits produced on two-shift days, with the labeled process running on both shifts.
- Line reviewIdentified where equipment, materials and pallet handling slowed output, and recommended fixes.
- Shared gainsOn this program, RELY passed efficiency gains back to the customer as the line got faster.
FULL PROGRAM · JAN 13 TO JUN 10, 2026
- Kits, highest recorded week
- 31,518
- Recorded production days
- 35
THE OUTCOME
The brand's retail timeline held.
Highest recorded day: 7,040 kits across two shifts. The added label did not extend the delivery timeline.
SOURCE: RELY INTERNAL PROGRAM RECORDS, JAN 13 TO JUN 10, 2026: 35 RECORDED PRODUCTION DAYS, INCLUDING VALIDATION RUNS. PRODUCTION DAYS ARE RECORDED DAYS, NOT CONSECUTIVE CALENDAR DAYS. CUSTOMER NOT NAMED. RESULTS REFLECT THIS PROGRAM ONLY AND ARE NOT A STANDARD LEAD-TIME OR CAPACITY COMMITMENT.
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The original PDF is available to download.