How CFS solved a customer’s mattress issue with high-speed delivery

CFS designed a whole new production and shipment process for an American healthcare company.

Custom Foam Systems Ltd. (CFS) supplies myriad foam components, including mattresses, for the healthcare industry. One of the advantages of working with CFS is its emphasis on speedy service and delivery. This came in handy when a healthcare facility in the United States needed a mattress core replaced – and needed it done within 72 hours, for a patient’s well-being and safety. As always, CFS was up to the challenge, and it prevailed.

A reliable and predictable process

The healthcare facility could not stock the product because of space constraints. So CFS was tasked with delivering a custom healthcare mattress core, complete with cover, directly to the facility within three days, at a cost that the customer could manage. Ground transportation would not be fast enough.

The only feasible solution was for CFS to develop a “level one” packaging specification for courier shipment – which entailed making a mattress core with a maximum height and circumference of 108 inches, without compromising on comfort or quality. The package would take 48 hours to reach the customer, so that left only one day.

CFS used its extensive materials and engineering expertise to develop a repeatable, safe method of simultaneously compressing, rolling, and polybagging the mattress while maintaining product integrity and intact packaging. The company built a new “compression-rolling” machine to meet the precise specifications.  A reliable and predictable process was necessary to meet this short deadline. So CFS partnered with a major international courier company to set up a small terminal with a specialized portal link that would streamline the communications and shipping process for the logistics team.

The solution required CFS always to have stock ready for shipment. The company accomplished this by implementing a Kanban replenishment process to manage inventory of the six different mattress cores it had manufactured for the program. The CFS team met the customer’s needs by shipping 6,000 mattresses through this process, averaging 125 per week.

This advanced solution enabled the healthcare company to secure new contracts, expand its business, and boost its reputation as a reliable, innovative provider – all with CFS’s assistance.

For more information, contact CFS.

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