Same day rack crate turnaround keeps customer on track for fit testing and high-volume production schedule
9 June 2026
One of our long-term customers came to us with an urgent problem. They needed a new rack measuring 90-1/2 inches tall and that included protruding components near the base.
Their existing rack crate configuration was incompatible with this set up. The problem was they had a strict fit-testing and large-scale production schedule which meant they needed this new rack crate designed and fabricated ready for testing in one day.
Solution
Given the urgency, the LPC design team came up with the clever idea to adapt an existing proven rack crate design rather than start from scratch. They selected the most appropriate starting crate and then:
- Modified the internal well walls and spacers to clear the new base protrusions.
- Increased the overall crate height to accommodate the taller rack.
- Recalculated the load distribution and adjusted the floater foam size and density to maintain proper load-bearing support for the new rack higher center of gravity and additional weight.
Results
By adapting an existing rack crate design with standardized rack crate procedures, materials, and cutsheets, the LPC design and fabrication team was able to move rapidly from design adjustment to full assembly within just a few hours saving, the customer’s schedule.
- The newly configured rack crate was delivered to the customer the same day for fit checks.
- The customer confirmed that the fit was precise, and the protection around critical components was excellent.
- They appreciated our responsiveness and the level of trust they could place in our process of delivering under tight deadlines.
- The customer’s internal testing schedule was saved and they were able to stay on track for high-volume production.