包装技术基础(双语教学).ppt

Lesson16,DistributionPackaging第16课运输包装,ShortHistoryofDistributionPackagingintheUSA,Distributionpackagingemergedinthe1800sastheindustrialrevolutionblossomedandmanufacturersbeganshippingtheirgoodsnationwideviarailroad.-Paperdidnotenterthedistributionarenaasprotectivepackaginguntiltheearly1900s,whencorrugatedboxesfirstappearedasshippingcontainers.-FromtheendofWorldWarItotheendofWorldWarII,theuseratioofcorrugatedtowoodcontainerswentfrom20/80to80/20.-PalletsbecamepopularforindustrialusefollowingWorldWarII,andunitizingofhigh-volumeproductsforshipmentacceleratedinthe1950s.-Plasticsbeganappearingintheearly1960swithvariousfoamsreplacingcorrugated,rubberizedfiber,andwood-basedproductsasinteriorpackaging.,FunctionsandGoalsofDistributionPackaging,Thefunctionsofdistributionpackagingcanbesummarizedasfollows:ContainmentProtectionPerformanceCommunication-Mostdistributionpackagingshouldaddressthefollowinggoals:Productprotection:EaseofhandlingandstorageShippingeffectivenessManufacturingefficiency:EaseofidentificationCustomerneedsEnvironmentalresponsibility,TheCostofPackaging,Itwasestimatedthatexpendituresforallpackagingmaterials,includingexpendable(one-way)shippingpallets,wereapproximately$100billionin1997.Ofthistotal,aboutone-thirdwasintheformofdistributionpackaging.-Thelargestsinglesegmentofdistributionpackagingiscorrugatedshippingcontainers,atapproximately20%oftotalexpendituresand60%ofdistributionpackagingcosts.-Ithasbeenestimatedthatalthoughactualfreightclaimspaidbycarriersfordamaginggoodsisapproximately$2billion,theactualcosttothemandtoshippersisreallymorethan$10billionperyear.-Ourgoalinpackagedesignistominimizethecostofbothpackaginganddamage.,ThePackageDesignProcess,Todevelopanoptimumdistributionpackagethatisbothfunctionalandcost-effective,youwillneedmorethanjustassistancefromyourpackagingsuppliers.-Althoughyourexperiencewithaproductlineandasuppliersexperiencewithpackagingmaterialsarebothhelpfulindesigningpackaging,bothofyoushouldconsidermanyfactorsinadditiontotheproductandthepackaging.-Yourscopeofconsiderationshouldincludeallaspectsofthedistributionsystem,includingcustomers,carriers,anddistributors,aswellasthemanufacturingplant,packagingline,warehousing,andshipping.Tobesuccessfulindistributionpackagedesign,takeatotal-systemapproach.,TakingaTotalSystemApproachtoPackageDesign,Oncecreated,apackagehasaninfluenceonandisinfluencedbyeveryoneandeverythingitencounters.-Mostoftheseencountersaffectmanufacturinganddistributioncostsorproductintegrity,withindirectimpactonsales.-Ageneralruleofthumbisthatthetotalcostoftransportationisbetween3and10timesasmuchaspackagingonaverageforallshipments.Asmallreductioninpackagesizeorweightcouldmeansubstantialsavingsintransportationcosts,aswellasinhandlingandstorage.-Aninverserelationshipexistsbetweenpackagingcostandmaintainingproductintegritywithlowdamagerates,asshowninFigure14.1.Anincreaseinpackagingcostsprovidesmoreprotectiontothecontentsandthereforelowersthepotentialfordamage.,TakingaTotalSystemApproachtoPackageDesign,Figure16.1Theoptimumpackagingsystembalancescostsfromexcessivedamagewiththecostsofoverpackaging,TakingaTotalSystemApproachtoPackageDesign,Therealcostofgettingtheproductsafelytomarketisthesumofpackaginganddamage.-Optimizingtotalcostisthetruegoalofpackagingdesign.-Nomatterwhereinthecompanyyourpackagingdesignfunctionislocated,inengineering,manufacturing,shipping,orelsewhere,trytoincludeallfactorsinatotal-systemapproachforanoptimumdesign.TheProtectivePackageConceptProduct+Package=DistributionenvironmentFigure16.2depictstheconsequencesofanimbalanceinthisequation,showingwhathappenswhenaproductplusitspackagearenotexactlywhatisneededtosurviveinthedistributionprocess.,TakingaTotalSystemApproachtoPackageDesign,Figure16.2Protectivepackageconcept,TakingaTotalSystemApproachtoPackageDesign,Severityisthequantitativemeasureoftheenvironment,whichcanbeanyoneoracombinationofhazardsindistribution.hazardsseveritytherough-handlinghazardto30inchesofdropa20-poundpackagethecompression(storage)hazard10packageshighinwarehousingthehightemperaturehazard1300F.Productrepresentsthemeasuredlevelofresistancetodamageoftheproduct.-Anoptimumsolution:theproductsmeasuredlevelofdamageresistanceplusthepackagingsmeasuredabilitiestoprotecttheproductareexactlyequaltotheexpectedenvironmentalhazard(s),TakingaTotalSystemApproachtoPackageDesign,Forexample,aproductwith15-inchdropresistanceispackagedinmaterialthatwilldissipatetheshockgeneratedinthe30inchesofdropheightthepackagedproductisexpectedtoencounterinthedistributionenvironment.-Whenthepackageprovideslessprotectivecapacitythanneededfortheenvironment,thisunderpackagingwillresultindamage.-Overpackaging.Thepackageprotectionlevelishigherthantheenvironmentrequires.-Itmaybepossibletoimprovetheproductasanalternativetomorepackaging.-Themostelusivepartofthepackage-plus-productequationisthedistributionenvironment.,The10-StepProcessofDistributionPackagingDesign,A10-stepprocedurewillhelpyoudesignadistributionpackagethatprovidesmaximumperformanceatleastoverallcost.1.IdentifythePhysicalCharacteristicsoftheProduct2.DetermineMarketingandDistributionRequirements3.LearnabouttheEnvironmentalHazardsYourPackagesWillEncounter4.ConsiderPackagingandUnitizingAlternatives5.DesigntheDistributionpackage6.DetermineQualityofProtectionthroughPerformance-Testing7.RedesignPackage(andUnitLoad)untilItSuccessfullyPassesAllTests8.RedesigntheProductifIndicatedandFeasible9.DevelopthePackagingMethods10.DocumentAllWork,AFinalCheck,Hereisanothersuggestion.Foranypackagedesignproject,aftercompletingthe10-stepprocedureabove,checkyourworkagainstthelistofimportantconsiderationsasfollows.Bydoingsoyouwillsignificantlyreducethepotentialforanunpleasantsurprisewhenshipmentsbegin.PackageDesignProjectChecklistHaveyou:1.Consideredthesolidwasteaspectsofthepackageandunitload,andtheiralternatives,tominimizeimpactontheenvironment?,AFinalCheck,2.Ponderedtheuseofreturnable/reusablecontainersanddunnage?3.Contemplatedallcostfactorsinthedistributioncycle:handling,storage,transportation?4.Comparedthecostofthispackagewithcompany/plantaveragesforsimilarproducts?5.Consideredallpossiblealternativesinmaterialsandmethods?6.Usedindustrystandardsformaterialsanddesigncriteriawherepossible?7.Performance-testedthedesignagainstacceptedindustrystandards?8.Documentedthedesignusingthecompanysspecificationsystem?9.Checkeddamageandcustomercomplaintsonthisproductline?10.Satisfiedallrulesandregulationsapplyingtothisproductforalldistributionmodesitisexpectedtoencounter?,TheWarehouse,Thedistributionwarehouseisacentralcollectingpointforaparticulargoodoraparticularmerchandisingchain.Finishedgoodsareforwardedtoandheldatthewarehouseuntilselectedandassembledintoacustomerorder.Thewarehouseenvironmentisnotwellunderstoodbymanyshippers.Atypicaldrygrocerieswarehousemaycontain20,000individualstockitems.Ahardwarechainwarehouseholdsupwardsof40,000stockitems.Productarrivesatthecentralwarehouseinbulkorunitized,isbrokendownorreunitizedaccordingtothewarehousesneeds,andthenisarrangedforstock-picking.Stock-pickingistheprocessofselectingindividualitemstofillanorderforaparticularstoreordestination.Centralwarehousesservelargecustomerareas;insomeinstancesoneortwowarehousesmayessentiallyservetheentirenation.,TheWarehouse,Aproductmustfitthewarehousesmaterialhandlingsystem.Thisoftenmeanspalletinglooseloadsorrepalletingloadsfromnonstandardpallets.Dependingontheoperation,anywherefrom33to70%ofproductreceivedatawarehousemustbehandledmanuallybeforeanorderisplacedinstock.Manualhandling,inadditiontobeingcostly,isalsoaprimarysourceofdamagefromdropping.Inthepickingaisles,stockmustbeclearlyidentifiablefromeveryside.Multicolorgraphicdisplaysserveonlytoobscurevitalinformationfromthepicker.AboxlabeledGoldenTriangleFarmsdoesnotinformthestock-pickerofthecontents.Containersshouldbestrongenoughtobedraggedoffthepalletbyoneend,andstiffenoughthattheydontdistortandreleasetheircontentswhenhandledinlessthanidealfashion.Glueflapsmusthaveenoughadhesivetoresistabusivehandling.,TheWarehouse,Anassembledordermaycontainitemsasdisparateaseightmirrors,sixassortedclocks,acaseofoil,fourshockabsorbers,astepladder,andaMepps#4fishinglure.Theseandotheritemsareassembledonamixedpalletfortransporttotheretailoutlet.Containersmustbeeasilyhandledbythepickerandshouldbereadilypackedontoamixed-orderpallet.Containerorientationonmixed-loadpalletswilltendtobeonabestfitbasis,regardlessofThissideupandDonotstacklabels.Itmaybepossibletopackatrapezoidalcontainerefficientlyonyourpallet,butoddshapesdonotpackwellinamixed-productpalletload.Useboxeswitharectangularcrosssectionwhereverpossible.,UnitLoads,PalletsItissimplertomoveone1,000-kilogramloadthanitistomoveathousand1-kilogramloads.Loadsaremostcommonlyunitizedonpallets,aplatformthatcanbepickedupbythetinesofaforklifttruck.Anothertechniqueusesslipsheets,toughfiberboardorplasticsheetsonwhichtheloadisstacked.Thetruckusedwithslipsheetshasaclampmechanismthatgraspsaprotrudingedgeofthesheetandpullsthesheetandloadontoaplatformattachedtothetruck.Athirdmethodofhandlingalargegroupofassembledobjectsiswithaclamptruck,amechanismthatpicksuploadsbyexertingpressurefrombothsidesoftheload.,UnitLoads,Eachmethodhasitsadvantagesanddisadvantages.Slipsheetsareeconomical,takeuplittlespace,andarelight.However,theequipmentisnotuniversallyavailable,ismoreexpensive,andisslowertooperate.Palletsareuniversallyadaptabletoavarietyofhandlingsituationsandlocations.However,palletsarecostly,takeupspace,andcanbedifficulttodisposeof.Clamptrucksusenoaddedmaterials,butthegeometryandcharacteroftheloadmustbesuchthatitcanbesqueezedbetweenthetrucksclamps.Mostpalletsaremadeofwood,andchoiceofwoodspecieshasagreatimpactoncostanddurability.Thedenserandstifferthewood,thegreaterthepalletsdurabilityandusuallythegreateritscost.Well-madehardwoodpalletsarethemostdurableandcost-effectiveoptionofthemanymaterialchoicesavailable.Othermaterialsareusuallyselectedforconsiderationsotherthandurability.,UnitLoads,Therearemanypossiblepalletsizesanddesigns;however,forthesakeofstandardizeddistribution,certainsizesanddesignspredominate.Byconvention,apalletssizeisstatedlengthfirst,withlengthdefinedasthetopdimensionalongthestringerorstringerboard(Figure16.3).Aboutathirdofallpalletsarenominally40by48inches,thestandardsetbymembersoftheGroceryManufacturersofAmerica.Thissizeisalsoveryclosetotheinternational1,000by1,200mmsize.Thetwobroadcategoriesofpalletdesignarestringerandblocktypes(Figure16.3).Arangeofvariationsisavailablewithineachdesigntype:,UnitLoads,Figure16.3Ablockpallet(left)andastringer-typepallet(right),UnitLoads,Reversiblepalletshavesimilartopandbottomdecks.Nonreversibledesignshavedifferenttopandbottomdecks,withonlythetopdeckdesignedtobeaload-carryingplatform.Wingpalletshavethestringersinsetsothatthedeckboardsoverhang.Thisallowsforthepalletstobehandledbyslings.Palletscanbesinglewingordoublewing,dependingonwhetheroneorbothdecksoverhangthestringers.Two-way-entrypalletshavesolidstringersandcanbeenteredonlyfromthetwoends.Block-typepalletsarefour-wayentry,sinceanyequipmentcanenterthepalletfromallfourdirections.Apartialfour-wayhasnotchescutintothestringerbottoms.Aforkliftstinescanenterfromanydirection,butahandtruckcanonlyenterfromtwodirections.,UnitLoads,Inadditiontoprovidingaproductplatform,thepalletisabufferagainstthehandlingenvironment.Aforkliftdriverplacingapalletintopositioncannotseetheexactplacementlocation:hestopswhenhehitssomething.Viewedinthiscontext,practicessuchasdeliberatepalletperimeteroverhangcanonlyleadtoproblems,andwarehouseoperatorscondemnthishabit.TheFoodMarketingInstituteholdspalletissuesresponsibleforabouthalfofallobserveddamageandcitespoorpalletfootprintasthesinglelargestcauseofshippingdamage.Ofthisdamage,50%isattributedtopoorpalletstabilityand35%isattributedtopalletoverhang.Palletmaintenanceprogramsareessential.Acommonandeasilyremediedproblemisfastenersworkingtheirwayoutofthewood.,UnitLoads,UnitLoadEfficiencyWarehousefloorspaceisrentedbyarea,andthemoreproductthatcanbeputintothatarea,thebetter.Trucksloadedwithlightproductshouldhavetheavailablevolumecompletelyfilledtocarrythemaximumamountofproductpertrip.Areaandcubeutilizationshouldbeeverypackagersconcern.Optimumareaandcubeutilizationbeginswiththedesignoftheprimarypackage.Primarydimensionsshouldbeconsideredintermsofpossiblepackingorientationsintheshippingcontainer,impactoncorrugatedboarduseintheshippingcontainer,andpalletingpatternandspaceutilization.,UnitLoads,“Arrangement”referstopackingpatternsusedwhenplacingprimarypackagesintoashipper.Traditionally,theproblemwassolvedthroughintuition,experience,andafewnominalcalculations.However,smallcartons,packed24toashipper,mayhaveoverathousandpossibleorientationandpalletingsolutions.Computerarrangementprogramsareavailablethatwillcalculatealltheimplicationsofsizedecisionsinminutes.Typicalinputdataforapalleting-efficiencycomputerprogramare:DatapertainingtotheprimarycontainerAllowedprimarydesignchanges,ifrequiredDatapertainingtotheproposedshippingcaseDatapertainingtopalletingrequirements,UnitLoads,Typicaloutputdataforsuchaprogrammightprovidethefollowinginformation:OptimumdimensionsfortheprimarycontainerOptimumpackingorientationsforselectedprimarycontainersInsideandoutsidecasedimensionsforeachselectedcasetypeNumberofunitsperpalletforeachprimary/caseoptionAreaandcubeutilizationforeachprimary/caseoptionRecommendedpalletpatterns,includingwalk-aroundviewsDimensionaldetailsofthepalletpatternMaterialareasusedinprimary,divider,andcaseconstructionRelativecostfactorsforeachconstructionRelativecompressionvaluesforcorrugatedboardconstructionsProposedmaximumwarehousestackingheights,UnitLoads,Athoroughsystemanalysis(includinglosses)canleadtosubstantialsavings.Amajorbusinessequipmentmanufacturerfoundthatithadpoorshippingexperiencebecauseofthehundredsofdifferentpackagesizesintheproductline.Thecompanydesignedamodularsystem,andallproductsweredesignedtofitoneof17standardboxsizes.Besidessignificantinventoryreduction,thecompanygainedsubstantialtransportsavings,sincelarger,morestablepalletloadscouldbebuiltwiththemodularsystem.More-securepalletloadsresultedinfurthersavingsthroughreducedproductdamage.,UnitLoads,StabilizingUnitLoadsUnitloadsoftenneedtobestabilizedinordertoretainloadgeometryandorderduringshippingandhandling.Strappingisusedmostlyforheaviergoods.Caremustbetakenthatstrappingdoesnotcutintothe