When Robert O’Donnell, Director of Purchasing for SixAxis, first connected with Morrisette Packaging, it wasn’t by chance — it was by persistence.
“I’d been trying to reach them for a couple of years,” Robert recalls. “One day, Roberto from Morrisette finally answered the phone. I asked, ‘Why today?’ and he said, ‘Because I didn’t need you then — but I need you now.’”
That one phone call turned into a game-changing partnership.
Morrisette was given just one product to quote. But that single opportunity grew into something much bigger — a collaborative relationship that transformed SixAxis’ packaging operations from complicated and costly to clean, efficient, and smartly designed.
The Challenge: Packaging Overload
SixAxis is known for its OSHA-compliant, configurable access platforms — large, precision-built systems that keep workers safe while improving productivity in industrial environments. But the packaging that protected these products wasn’t living up to the same standard.
“It was a hot mess in a box,” says Robert. “We had packaging components that were excessive and inefficient. It took too long to assemble, used too much material, and still didn’t protect the product the way we wanted.”
When Bill Cotton from Morrisette’s Design Center walked into the packaging area for the first time, he immediately saw the opportunity.
“His eyes got big,” Robert laughs. “He said, ‘We can definitely do something with this.’”
The Collaboration: Reimagining Every Box
Morrisette’s design and engineering teams got to work — not by guessing, but by collaborating. Over a period of six months, they partnered closely with the SixAxis crew to analyze, prototype, and refine each package.
“We’d take a couple of packages at a time,” says Robert. “We’d prototype them, review, make adjustments, and repeat. By the end, we had redesigned 12 different packages — and every single one performed better.”
One of the biggest wins came from simplifying the internal packaging.
A product that once required 17 inserts was reduced to just 7, offering better protection with half the components.
The improvements didn’t stop there. The team eliminated the need for stretch wrap on Fair Treads products by designing new custom-fit boxes that hold the items securely in place. This change made packaging faster, safer, and easier for the production team — and they couldn’t be happier.
The Results: Fewer Parts, Better Protection, Lower Costs
By the end of the redesign project, SixAxis achieved measurable, meaningful results:
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50% reduction in internal packaging components
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Improved protection and reduced damage during transit
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Faster, more efficient assembly on the production floor
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Lower material costs and a more sustainable packaging footprint
“It was a true collaboration,” Robert says. “Everyone won — Morrisette, SixAxis, and most importantly, our people on the floor. Morrisette helped us find solutions that made sense both operationally and financially.”
The Partnership: Trust, Growth, and Innovation
SixAxis takes pride in its commitment to OSHA compliance and ISO 9001 & 14001 certification, maintaining the highest standards for safety and quality. Working with partners like Morrisette helps them stay true to that mission.
“Anyone considering a partnership with Morrisette Packaging — I’d strongly suggest it,” Robert says. “It’s been a great two years. They’ve helped us grow, they’ve been strategic, and they’ve pushed us to innovate. It’s been a truly great relationship.”
Final Takeaway
The SixAxis and Morrisette partnership proves that when companies work together with shared goals and open communication, innovation naturally follows.
What started as a cold call turned into a story of persistence, trust, and transformation — one box at a time.
