As businesses expand, analyses of effective production, storage and transportation are essential. Trulite Glass and Aluminum Solutions posed a question to Clemson’s student researchers: What are the most efficient methods for delivering their main products, glass and aluminum panels, to construction sites and vendors with minimum breakage? This complex problem required a interdisciplinary approach. Thus was formed the Trulite Shipping and Next Generation Packaging Corporate Creative Inquiry project, with two disciplinary teams under the guidance of Dr. Bill Ferrell in the Department of Industrial Engineering and Dr. Gregory Batt in the Department of Food, Nutrition and Packaging Science. The students are using Trulite’s data and observations at Trulite facilities to propose solutions to the multipronged issues. Taking into account the packaging of the glass panels, distribution of demand points and locations of Trulite production facilities, the Creative Inquiry students were tasked to minimize loss and to conceptualize efficient and economical systems for packaging and delivery. Trulite was interested in possible alternative containers for transporting glass. They currently use expendable wood racks and challenged the packaging science team to develop a rack that was more cost efficient and that better protected the glass. Further, Trulite wanted to expand distribution options beyond using their own trucks to include the use of commercial carriers so the team tested the forces that the Trulite racks undergo during transport. They used this test plan to evaluate the current glass packaging, observe rack handling at construction sites and partner with a local metal rack supplier to develop and prototype an alternative rack system. While the packaging science team is examining designs for packaging, storing and transporting glass panels, the industrial engineering team is analyzing current production and shipping patterns to develop a plan to maximize efficiency of manufacturing and deliveries. The industrial engineering team analyzed Trulite data to map the distribution and density of past projects to identify ways to increase distribution efficiency and effectively grow into new markets. Initial recommendations include ideas such as realigning production in different plants, adding distribution centers and developing different delivery strategies. This team is determining realistic options to handle the market growth projected for Trulite that would include both additional capacity of product and increased flexibility in their manufacturing facilities. The team used a specialized software package, eSpatial, for data visualization that helped both the team and Trulite decision-makers better understand the data and possible solutions.

The two teams have each developed relationships with Trulite through biweekly meetings and site visits to production plants. “We did two site visits, one each semester, but it was the first one that was our starting ground to visualize both the problem and possible solutions,” Liz Parler, a senior industrial engineering major, explained. During one visit, the team had the opportunity to hear Trulite’s CEO speak about the past year’s business and the projection of the next year’s success. “It was nice to see our own goals for the project and how it coincided with the CEO’s vision of the company moving forward,” Isaac Fields, a senior industrial engineering major, said.

This Corporate Creative Inquiry project and relationship with Trulite is giving students the opportunity to experience seeking solutions to the complex problems of market growth and product loss. Trulite will consider implementing the students’ research, tests and ideas to enhance their production, delivery and packaging methods through minimized loss of glass products and strategic distribution of manufacturing plants and distribution centers. “Working in conjunction with both the Packaging Science and Industrial Engineering Departments has enabled us to leverage diverse skill sets and consider significant improvements to our existing production, packaging and supply chain network. We’ve enjoyed working with the Clemson students and the value they bring to our organization,” John Schmitt, Director of Procurement at Trulite, said. Both teams will continue working on this project with Trulite in the fall.

– by Alyssa Haygood-Taylor