Sustainability Report - Dell

Packaging Optimization—Dell's Server PackDesigned with Austin Foam PlasticsAn example of ourpackaging optimizationwas Dell's server packdesigned with AustinFoam Plastics, whichreceived AmeriStarWinner and Worldstar forPackaging awards.The packaging, based on all-corrugate design, removes7.8 pounds of wood from the pack, resulting in 277 tonsreduction in annual wood usage. The packaging is alsoresistant to the wood beetle infestation, a commonproblem for wooden pallets, and does not require heattreatment or fumigation with Methyl Bromide.if shock inputs are well below product fragility levels, packagingmaterials can be reduced. The goal for Dell is to use theright amount of protective packaging to deliver a qualityproduct to the customer.Last year, Dell worked at reducing packaging and increasing thedensity of components in shipping containers throughout oursupply chain. Our Worldwide Packaging Engineers worked withthe supply chain to identify which component packaging couldbe minimized. Inbound packaging was redesigned to reducepackaging and increase product density, which leads to fewertruck shipments, less gasoline consumption and reduced emissions.Lastly, all packaging material coming into Dell's manufacturingsites is sent to a recycler to be sorted and recycled.Eco-Delivery ProjectFor large volume purchases, Dell offers a reusable cratingsystem that reduces packaged product volume and storagespace by about 40 percent. This crating system containsmultiple systems protected at the highest quality from thehazards of shipping and handling environments. The containerused in this crating system is returned to Dell and reused forother bulk orders.An example of our success in implementing this system wasthe use of Eco-Delivery for shipping Dell workstations to PennState University. This method provided the following benefits:Packaging OptimizationPackaging optimization starts with a product. Dell's Shock andVibration Engineers perform extensive tests on the product,simulating worst-case shipping and handling environments. Byworking closely with the product design engineers, enhancementsare made to a product and then tested until the robustnessof the product is improved. This increased product robustnessresults in less packaging material required to protect theproduct, which results in the reduction of packaging materialmanufactured and disposed of into the waste stream.After the robustness of a product has been established, thepackaging engineers develop packaging. Using electronicallymonitored models and products, engineers measure the shockand vibration inputs that the packaging produces during testing.If levels to the product do not meet the specification,packaging is improved until requirements are met. However,• Deployment time was dramatically reduced from four days tojust 2.5 hours for each shipment.• All on-site waste material was eliminated.• The per system deployment cost was reduced to $12 from acost of $35 the previous year.Dell has expanded this program to include OptiPlex mini-towerand small form factor desktop products, and the LatitudeD610 notebook.Eco-Delivery Success with Penn State University"Last year it took us close to four days to unbox andprepare 120 CPUs for delivery to our labs. This year(with Eco-Delivery), it took us only 2 ½ hours from thetime the machines were off the truck to being ready fordeployment….Overall, we have been very pleased withour initial experience of Eco-Delivery and our team islooking forward to the next shipment."Jonathan Holman of Penn State UniversityInformation Technology Services54 D E L L S U S T A I N A B I L I T Y R E P O R T • F I S C A L Y E A R 2 0 0 6