Case Studies
Print Kit Ship
In the wake of remarkable new business growth, Subaru was looking for ways to streamline their print & fulfillment processes. With decades of Print-Kit-Ship experience, Tweddle Group helped Subaru meet increasing demand for their product information and established a decades-long partnership.
Overview
Tweddle Group was able to resolve multiple pain points for Subaru, helping them overcome space and growth concerns—and the limitations of manual kit assembly—with improved delivery times and incredible quality. Our Subaru partnership has continued to progress for more than 20 years, as Tweddle Group supports their evolving needs and ongoing drive for sustainability.
The Problem
Like all automotive OEMs, Subaru needed a solution for the printing, kitting and distribution of their owner information. Previous solutions had required Subaru team members to manage a variety of different suppliers, each with their own timelines and requirements, and then coordinate them as a group to ensure on-time delivery of final products. But as Subaru vehicle sales increased, reducing the number of individual suppliers tied to specific deliverables would help streamline the process.
Subaru wisely sought an end-to-end solution covering all manufacturing, assembly and fulfillment. The goal was to enhance quality while minimizing wasted time and cost, and to streamline an otherwise chaotic undertaking. However, to make this decision workable, they’d need a supplier they could trust, someone experienced and well-equipped to handle every aspect of the project, worry free.
Tweddle Group offered proven end-to-end capabilities, plus authoring and other services beyond printing & fulfillment.
The Challenge
Subaru required a high level of quality, speed and accuracy for their print fulfillment. Many other suppliers assemble and inspect their kits manually, by hand, in lieu of automated assembly with built-in quality checks. This method leads to low quality control and high levels of error.
Subaru’s returnable tote program—which recycles transport containers for reuse through successive shipping operations—provided an additional layer of complexity. Tote inventories would need to be stored, tracked and managed for consistent shipping and receiving.
The Process
Tweddle Group’s automated assembly systems feature multiple layers of quality control, leveraging both barcode tracking and weight scanning in an industry where competitors typically rely on one or the other.
The system applies bar codes to every part of the process. Bar code scanners monitor quality and placement throughout the printing, binding and assembly phases. Tweddle Group weight scales and bar code systems are calibrated to detect the slightest error, identifying the errant inclusion or absence of a single business card.
Tweddle Group Print Kit Ship performs physical quality and sample checks at the file, print, component and kitting levels. This same eye for detail helps manage kit inventory and logistics for Subaru, delivering their finished kits to a variety of ship-to locations.
Tweddle Group’s commitment to Subaru’s quality parts and products is reflected in every aspect of the process. To ensure we satisfy and exceed all customer expectations, Tweddle Group and Subaru each maintain separate project scorecards. This is a standard Tweddle Group practice, bringing critical oversight to all print and fulfillment KPI tracking.
The Solution
Tweddle Group’s Subaru partnership began in 2002, and initially covered Subaru’s printing concerns. The work expanded in 2007 to include kitting and portfolio support, and again in 2008 with the addition of authoring support.
In total, Tweddle Group’s Subaru partnership today encompasses the following range of products and services:
- Developing content
- Receiving files
- Prepping files for print
- Printing, binding and finishing
- Assembling vehicle-specific kits with parts installed into portfolios
- Managing the bill of materials in our ERP system
- Maintaining inventory and monitoring demand to support each component and vehicle-specific kit
- Managing delivery network for specified N. American delivery locations
Tweddle Group forecasts demand for Subaru’s kit inventory, always ensuring appropriate stock levels. And we successfully manage the client’s complex returnable tote program which bolsters sustainability and cost-effectiveness.
Tweddle Group’s skilled and experienced team members leverage a variety of proven best practices, tackling all customer requirements with maximum care and flexibility.
The ResULt
Our Print & Fulfillment scorecard bears out a remarkable record, applying to Subaru as well as our other PKS customers:
- 100% on-time delivery
- 99.7% inventory accuracy
- Zero PPM (zero parts-per-million, i.e., no defects per one million parts produced)
For over two decades, Tweddle Group has delivered stellar products and service for Subaru. With an aggressive eye toward continuous improvement and project optimization, we’ve taken ownership of Subaru’s primary concerns—starting with quality and speed, then going above and beyond to create new cost savings and new carbon footprint reduction opportunities.
