Case Study: International Toy Brand Streamlines Operations and Cuts Production Costs with RR Donnelley

International Toy Brand cuts production costs by double digits with RR Donnelley

An international toy brand faced challenges in optimizing its packaging supply chain as global demand grew. They needed to consolidate the production of labels and manuals in Asia, a move complicated by technical constraints like laminating a 12-page manual with labels and working with a new single-sheet manual that had tight tolerances. They partnered with RR Donnelley to achieve their goals of reducing shipping costs, improving lead times, and streamlining operations.

RR Donnelley implemented an integrated solution where their engineers devised an innovative way to combine lamination and die-cutting processes. This improved production output fourfold and qualified new, strong yet removable adhesives. The partnership resulted in a seamless relocation that significantly reduced logistics costs and shortened lead times. Process enhancements led to a double-digit reduction in production costs, and RRD supported successful new product launches across more than 1,000 SKUs, positioning the toy brand for sustainable global expansion.