Republic Plastics Achieves Costs Savings Through LeanTMS® Visibility

Client Profile

Established in 1999, Republic Plastics manufactures premium private label foam products for the consumer retail and institutional foodservice tableware markets which compete with national brands. Republic Plastics supplies most US grocery retailers with private label tableware solutions including plates, bowls, saucers and lunch trays.

Republic Plastics has four processing facilities strategically located in the US to maximize distribution efficiencies. The company spends about $8 million per year in freight.

Business Process and Problem Definition

As a fast expanding company, Republic Plastics was quickly outgrowing its spreadsheet and fax- based transportation tracking. In addition to expanding business challenges, Republic Plastics was seeing a shift in freight transportation to a more regionalized approach. The company traditionally shipped freight in long distances of about 1,500 miles until retailers began opening more regional distribution centers, allowing product into the stores more quickly. The average shipping distance decreased to 500 miles, which adds time and complexity to the transportation planning process.

Republic Plastics wanted a transportation management system that could reduce time devoted to logistics planning and decrease transportation costs while the company continues to grow and evolve. The company values all employees and wanted the right technology to increase the efficiencies of the transportation team.

Republic Plastics created a list of goals for a transportation management system:

  • Eliminate high start-up costs with SaaS platform
  • Provide full management of transportation functions
  • Maximize efficiency of staff
  • Provide detailed metrics and reports
  • Improve customer service
  • Lower freight spend


Process Improvement – SaaS Solution

Republic Plastics chose LeanTMS® to manage outbound transportation from the manufacturing plants and distribution centers direct to retail stores. LeanTMS is a comprehensive, SaaS-based Transportation Management System (TMS) that fosters collaboration among all trading partners, monitors carrier performance, automates procurement, streamlines settlement, and optimizes shipping processes. Republic Plastics chose the LeanLogistics SaaS model because alternatives had higher costs across the board for initial fees, upgrade costs, maintenance charges, supplemental reports and ongoing support.

LeanTMS fosters collaboration by providing authorized staff, carriers, and customers with different views into the transportation process which reduces the burden on the entire transportation department. LeanTMS provides the ability to manage transportation remotely by logging onto the system from anywhere in the world to see shipment statuses in realtime.

Additional capabilities of LeanTMS to Republic Plastics include the ability to:

  • Optimize shipping
  • Monitor carrier performance
  • Gain visibility into freight movements
  • Improve collaboration among facilities and suppliers Gain in-depth reporting capabilities

Value Delivered

With LeanTMS, Republic Plastics obtains an industry-leading TMS with rapid implementation driving a lower cost. Republic Plastics is a mid- size manufacturer and with LeanTMS is able to afford a TMS solution built for some of the world’s most complex supply chains. Republic Plastics appreciates that the implementation and support of LeanTMS by industry experts at LeanLogistics requires fewer internal IT resources. Plus, with the SaaS-based software platform, LeanLogistics regularly introduces new features with automatic upgrades that Republic Plastics can use without any additional internal IT resources.

Republic Plastics is able to report at a granular level with LeanTMS to improve profitability of shipments and customer service. Republic Plastics transportation team creates reports down to the order level detail of how many cases per order, which allows them to track buying patterns.

The benefits Republic Plastics continues to receive from LeanLogistics include:

  • Lower freight costs
  • Improved shipment and costs visibility
  • The ability to collaborate internally and externally
  • Better team efficiency and productivity

Download the “Republic Plastics Achieves Cost Savings Through LeanTMS® Visibility” case study.