International Toy Brand Streamlines Operations, Reduces Production Costs | Manufacturing
7/21/2025
RRD Asia’s support results in significant improvements across supply chain, operations, and packaging performance
CHALLENGE
A fast-growing international toy brand sought to optimize its packaging supply chain. As global demand for their products increased, the company aimed to consolidate the production of labels and manuals in China — relocating these from a previous site in North Africa.
As it stood, the brand faced technical constraints. A 12-page manual required lamination with labels, but in-house capabilities were initially limited. A new single-sheet manual also introduced challenges when it came to material thinness and tight tolerance requirements.
Ultimately, the company required a partner who could execute the transition of the labels and manuals seamlessly while maintaining quality. They sought support in achieving their goals of reducing shipping costs, improving lead times, and streamlining operations.
SOLUTION
The toy company partnered with RRD Asia to address their objectives. Following a proactive collaboration during the transition, RRD was able to deliver a fully integrated and responsive solution that aligned with the company’s needs.
RRD engineers devised an innovative way to combine the lamination and die-cutting processes, improving the company’s production output fourfold. In addition, RRD worked with the company to qualify adhesives that were not only strong but also removable.
To accommodate the growing global demand for the company’s toys, RRD expanded their monthly production capacity. This initiative enabled the company to have greater flexibility in response to volume fluctuations.
RRD also provided compliance support by way of essential certifications required in the toy industry — building credibility and ensuring smooth onboarding with global retailers.
RESULTS
The partnership resulted in significant improvements across the toy company’s supply chain, operations, and packaging performance. Results included:
- Streamlined operations: The production relocation was seamlessly executed, significantly reducing logistics costs and shortening lead times
- Cost savings: Process enhancements led to a 20% reduction in production costs without compromising on quality or consistency
- Excellent NPI performance: RRD’s R&D and operations teams supported new product launches across 1,000 SKUs — including packaging development and color management
- Sustainable scalability: Enhanced capacity and improved workflows positioned the toy brand for continued global expansion — supported by a stable and responsive packaging supply chain