WayhomartCase Studies
How we have solved specific tooling and compliance problems.
Cutting dish rack freight with knock-down frames
A European kitchenware importer was paying to ship air on a welded dish rack. Re-engineering the frame as knock-down cut container volume without changing the retail appearance.
- PlaceholderSmall-batch colour change on a shared linemin 1600px · photo
Small-batch colour change on a shared line
A small first order with a brand colour can work without new fixtures, provided the change stays inside the powder line and colour judgment is anchored to a physical standard.
- PlaceholderAdding a hook: a basket change at the accessory layermin 1600px · photo
Adding a hook: a basket change at the accessory layer
The trap when adding a hook to an existing basket is assuming it has to be welded in the same fixture. Make the hook a separate part and no new fixture is needed.
- PlaceholderShoe rack trial on an existing KD framemin 1600px · photo
Shoe rack trial on an existing KD frame
To test flat-pack acceptance you do not need a new structure. Use the existing KD configuration, but send several samples so assembly and stacking are both validated.
- PlaceholderMedium volume, shelf-ready: sizing a dish rack colour boxmin 1600px · photo
Medium volume, shelf-ready: sizing a dish rack colour box
A colour box costs volume. Cut the dieline from measured samples, replace the foam with paper-card locating, and approve a white sample before anything is printed.
- PlaceholderTwo SKUs in one container: splitting volume by CBMmin 1600px · photo
Two SKUs in one container: splitting volume by CBM
A mixed container is not two sets of cartons pushed together. Convert both SKUs to CBM per unit, set the ratio, then stack by weight and size so the packing list matches the wall.
- PlaceholderThree colours on one shelving seriesmin 1600px · photo
Three colours on one shelving series
Launching a shelving series in three colours is not a colour-matching problem, it is a changeover problem. Collapse the tones into one family and put them in a single window.
- PlaceholderCan organizer tooling: welds become formingmin 1600px · photo
Can organizer tooling: welds become forming
At high volume the cost of a can organizer sits in multiple welds. Tooling rarely saves material — it removes process steps and makes step-offs more consistent.
- PlaceholderFlat-pack shelving: tiers, frames, nestingmin 1600px · photo
Flat-pack shelving: tiers, frames, nesting
There are three layers of volume reduction — knock down, share, nest. Used together they change container loading; used carelessly they tie two SKUs to one design.
- PlaceholderTwelve SKUs, four colours: staged releasesmin 1600px · photo
Twelve SKUs, four colours: staged releases
Twelve SKUs and four colours is a changeover problem, not a capacity problem. Two colour releases, structure-based batching and a frozen window make the schedule possible.
- PlaceholderPrivate-label wine racks: three documentsmin 1600px · photo
Private-label wine racks: three documents
An exclusive structure is not a promise in an email. It lives in three documents: tooling and fixture ownership, the scope of exclusivity, and the inspection standard built on signed samples.
- PlaceholderBathroom rack trial: mounting before finishmin 1600px · photo
Bathroom rack trial: mounting before finish
A bathroom rack trial rarely stalls on shape. It stalls on fixings and on the corrosion route: the wall decides mounting, the location decides material and finish.
- PlaceholderTwo- and three-tier bathroom racks: shared postsmin 1600px · photo
Two- and three-tier bathroom racks: shared posts
Extending a rack range from two tiers to three changes only the post length. Shared parts save fixtures, and the cost shows up in carton height, instruction paging and first-article checks.
- PlaceholderBathroom accessory sets: three items, two boxesmin 1600px · photo
Bathroom accessory sets: three items, two boxes
The hard part of a set is not the items but the fixing bags and short shipments. Three sub-families differ in size, so decide what shares a carton before deciding how many bags.
- PlaceholderWood and wire on a kitchen rack: pack them apartmin 1600px · photo
Wood and wire on a kitchen rack: pack them apart
An acacia base next to wire in one carton means scratches. Packing them apart is not work for its own sake; it keeps inspection and replacement traceable.
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Tell us the application, target market and annual volume. Our engineering team will review feasibility, tooling and lead time.
