About the company
Two of Mexico's leading cable operators, providing telephony, internet and cable TV services to more than 15 million users and reaching more than 60 cities in the country, needed a supplier to provide protective enclosures capable of safeguarding their equipment (fiber optics and ducts) in their subway networks.
The challenge
These telecommunications companies were facing the migration of their fiber optic networks from aerial to subway. For this reason, they needed a resistant, durable and anti-vandalism product, since the container boxes available in the market are usually made of polymer concrete or steel, a material susceptible to being stolen after being installed.
This need represented for FYCO the opportunity to develop a totally new product tailored to the requirements of customers in a demanding and large market.
“It is fascinating how a protectionist idea drove the development of these container boxes in Mexico. We were able to design a new and competitive product, modular and easy to fit together like Lego, made with sustainable raw materials, which impacts on the care of the environment and represents significant savings in logistics for customers.”
CEO Shellbox
The strategy
- A product tailored to the customer
To develop this new container box, an attempt was initially made to use the patent of a previously manufactured modular register. However, this product did not meet the technical specifications necessary to be used in Mexico, so a product specially adapted to these requirements was developed. For this adaptation, recycled polyethylene was used, which added an attractive sustainability feature to the product. Thus, “Shellbox” was born, a protective box for subway telecommunications materials specially created for the Mexican market.
- Innovative and sustainable design, inspired by nature
The name Shellbox is inspired by nature and alludes to the hardness and longevity of the turtle's shell, a shield that is synonymous with strength and durability in the animal kingdom. In addition, it is closely related to recycled polyethylene, which, in the form of bags, is the main threat to sea turtles' lives, which tend to ingest them, mistaking them for food. Thus, by reusing this polyethylene and preventing it from reaching the sea as waste, Shellbox contributes to preserving the life of sea turtles.
The creation of the identity of this new product was the result of an effort by the entire FYCO team, which, in the context of the pandemic, dared to think creatively to come up with the name and logo.
Today, Shellbox comes in 4 different sizes, each named after an endangered sea turtle: Kempii, inspired by the Olive Ridley Sea Turtle; Mydas, inspired by the Green Turtle; Carett, inspired by the Loggerhead Turtle; and Cori, inspired by the Leatherback Turtle.
- Single snap-on lids
Another advantage of this new product was the simplification of the assembly of the covers, which went from having 4 screws to just 1. This makes assembly easier and has a great impact on the installation process.
- A modular and lightweight product
Designed as a modular product, Shellbox is easy to handle and assemble, and does not require, for example, a crane for handling, which facilitates transportation and generates significant savings in logistics. From a central warehouse in the city of Querétaro, distribution was organized to cover the entire territory through the rental of warehouses located near each city where the products were to be delivered.
- FYCO Learning: training
Since Shellbox boxes fit together in a modular way, “like Lego”, FYCO developed a training system for the technicians of the companies that install the product: FYCO Learning. This platform includes a guide for the logistics, storage, transport and assembly of the product.
“The Shellbox factory is located in Teotihuacán, famous for its pyramids, which can be seen from a product dune located at the factory. In addition, the train that connects to the United States passes through there. This presents an opportunity to speed up Shellbox exports to that country. But the most important thing is that the growth of this factory attracted local people, bringing more people into the project and generating a positive impact on the community of Teotihuacán.”
CEO Shellbox
Figures
- 3 years of development required for this product from the initial idea
- More than 6,000 units sold to date
- 20% savings in production costs
- 5 countries are testing the product in addition to Mexico: USA, Uruguay, Venezuela, United Arab Emirates and Germany
- 3 regions will be impacted globally thanks to the scalability of the product: America, Asia and Europe
Results
- A resistant and vandal-resistant product
Shellbox containers are premium quality products, which comply with American SCTE standards, and guarantee a load-bearing capacity of between 15 and 20 tons, as well as high resistance to flammability. Furthermore, since it does not use steel or iron among its components, it is not attractive to theft, which is an advantage over other products available on the market, which are highly vandalized. Shellbox works like a “plastic safe”, but with the properties of steel.
- Logistics savings
The design of a logistics system with warehouses throughout Mexico, cupled with the modular and lightweight nature of the product, allowed for cost savings and optimization of delivery times required by customers. In addition, this logistics system set a precedent for FYCO as a future strategic supplier for other telecommunications companies in Mexico, since the country is currently experiencing a boom in the implementation of subway communication networks.
- A product line for every need
The success of the first Shellbox, in 4 different sizes, encouraged FYCO to develop new sizes of container boxes to meet the requirements of future customers.
- Proudly Mexican
The factory that was involved in the initial development of the product became the main producer of Shellbox boxes in Mexico. This not only allowed for a 20% reduction in manufacturing costs, but also had an impact on the community of Teotihuacán, where the factory is located, as new employment opportunities were generated and the payroll was increased from 20 to 50 employees.
- Scalability: from Latin America to the entire world
The development of an innovative product for this category also represented an opportunity to have a globally attractive product. By using recycled raw material, Shellbox offers fewer restrictions for export to other markets, allowing FYCO to scale its offer not only to Latin America but also to other regions of the world: tests have already been carried out in Uruguay and work is underway in Venezuela, the USA, the United Arab Emirates and Germany (which has enabled the approval process to begin for the whole of Europe). This is undoubtedly a case of Latin American innovation for the rest of the world.
- An attractive product for multiple industries
The product is not only suitable for telecommunications, but can be used in a very broad market, including all types of electrical installations for alternative energies, such as wind or photovoltaic, as well as water pipelines and civil works constructions.
- Continuous improvement
As part of the market demand for compliance with high quality standards, we are continuously working on updating and improving the product.