Case Study: a leading commercial truck manufacturer achieves $5.2M in reusable packaging efficiency with Decklar's Decision AI and automation

Leading Commercial Truck Manufacturer boosts reusable packaging efficiency by $5.2M with Decklar

A leading commercial truck manufacturer faced significant challenges managing its fleet of over 5,000 reusable totes. Totes were idling for extended periods at downstream locations, disrupting just-in-time supply flows and forcing the company to spend heavily on emergency disposable packaging. The manufacturer partnered with Decklar to fix this underlying circulation problem instead of purchasing additional inventory.

Decklar implemented its Reusable Asset Automation AI platform, which used existing data to autonomously manage the tote fleet. The solution provided real-time visibility, predicted supply-demand imbalances, and automated recovery tasks. Decklar's platform delivered a 53% reduction in stranded totes and increased active tote availability to 92% at one plant, saving over $15,000 in annual labor. Projected across all 28 plants, Decklar's solution is estimated to deliver a total annual impact of $5.2 million through cost savings, capital efficiency, and revenue growth.