缓冲包装设计七步法

1、 Lesson 16 Distribution Packaging 第第16课课 运输包装运输包装美国的运输包装的历史美国的运输包装的历史 随着19世纪工业革命的爆发运输包装出现,生产商通过铁路在全国范围内运他们的货物. - 知道20世纪早期纸制品作为具有保护性的包装进入运输领域, 这时瓦楞纸箱首先作为运输容器出现. - 从第一次世界大战结束到第二次世界大战，瓦楞纸板和木质的集装箱使用的比例从20/80 到80/20.- 从第二次世界大战开始货盘对于工业来说变的流行, 在20世纪50年代随着海运的增多，促进了运输包装的发展. - 在20世纪60年代随着各种泡沫代替了瓦楞纸板塑料开始出现, 橡胶

2、纤维, 木制产品作为内部的包装. 运输包装的功能和目的运输包装的功能和目的 运输包装的功能主要有以下几点: 容量 保护性 性能 交流 - 绝大多数运输包装都应该有以下目的: 产品的保护性: 易于处理和存储 运输的效率 生产效率: 易于识别 客户需要 环境责任 包装的花费包装的花费 据估计所有包装材料的支出,包括运输的货盘在1997年接近100万美元. 在花费的总数上大约三分之一是以运输包装的形式花费的. - 在运输包装中最大的部分是瓦楞纸板的运输集装箱，大约占总花费的20%和运输包装花费的60%. - 据评估通过空运对货物造成的损坏大约为20亿，对于货物和发货人接近100亿每年. -我们对包装

3、设计的目的是使包装和损坏最小化. 包装设计的方法包装设计的方法 为了设计出从功能齐全和划算的而且最适宜的运输包装，你不仅需要来自包装供应商的帮助. - 虽然你对于产线的经验和对包装材料供应商的经验对你进行包装设计有益处的，你们应该考虑除了产品和包装以外的其他因素. - 你考虑的范围应该包含运输包装系统的所有方面, 包括客户，运货人，发货人和产地，产线，和仓储，运输环境. 为了运输包装设计能够成功要考虑整个系统. 在包装设计中考虑整个系统影响在包装设计中考虑整个系统影响 一旦设计完成,包装会被它所遇到的每个人和每件事所影响. -遇到的绝大多数情况会影响到生产和运输的花费对销售也有间接的影响。-通

4、常凭经验来说运输的整体花费在整个运输的包装水平来说是3-10倍 在包装的尺寸和重量上一个小的缩减量都意味着在运输花费和操作中以及储存过程中的节省. - 在包装花费、保护产品完整性和降低损坏之间存在反比关系。,如图16.1所示.在包装花费上的增加对内部提供了更多的保护，从而降低了损坏的发生的可能性。在包装设计中考虑整个系统影响在包装设计中考虑整个系统影响图图16.1 从过度包装的额外损坏得出的最适宜的包装系统从过度包装的额外损坏得出的最适宜的包装系统的平衡体系图的平衡体系图 Taking a Total System Approach to Package Design 产品安全的投放市场的真实

5、花费是包装和损坏的总和. - 总成本的最优化是整个包装设计的目标. -无论在哪家公司你的包装设计的功能是固定的，在工艺上、生产上、运输上和其他。在整个系统最优化的设计中所有因素都要考虑进去。保护产品的概念 产品+包装= 分布环境 图 16.2 描述了在此展示了不平衡的方程。展示了产品加上包装在运输过程中所必需的. 对于包装设计采用的整个系统的方法对于包装设计采用的整个系统的方法图图 16.2 保护性包装的概念保护性包装的概念 对于包装设计采用的整个系统的方法对于包装设计采用的整个系统的方法严谨是对环境（在运输过程中的任何人或有害的化合物）的定量的方法. 有害 严谨大体上有害物质是每20磅包装中

6、 30英寸的跌落 在高温中仓储的有害物质的含量 在仓储中1300F10个包装件的高度代表在产品抵抗损坏的方法. - 一个最优的解决方案: 产品抵抗损坏的方法加上包装的测量能力是等同于在环境中的有害物质。对于包装设计采用的整个系统的方法对于包装设计采用的整个系统的方法例如：一个产品从15英寸跌落产生的震荡的抵抗力是包装材料在运输环境里在30英寸发高度跌落等同的效果。. - 当包装提供了比运输环境中需要保护少时，包装不足将导致损坏. - 过度包装. 包装保护的水平高于环境的需要. -这将会改善产品对于包装的选择性. - 包装加产品最难处理的 部分是运输环境. 运输包装设计的运输包装设计的10步法步

7、法 10步法将帮助你设计一个在全部成本上提供最高性能的运输包装设计。. 1. 产品自然特性的识别产品自然特性的识别 2. 测定市场和运输需要测定市场和运输需要 3. 了解你的产品所遇到的环境中的有害物质了解你的产品所遇到的环境中的有害物质 4. 考虑包装和单位化的替代品考虑包装和单位化的替代品5. 设计运输包装设计运输包装 6. 通过性能测试来决定保护品质通过性能测试来决定保护品质7. 重新设计包装重新设计包装 (单位的负荷单位的负荷) 直到能成功地通过所有测直到能成功地通过所有测试试8.如果有必要而且是可行的，重新设计产品如果有必要而且是可行的，重新设计产品 9. 进一步提高包装方法进一步提

8、高包装方法 10. 所有的文件存档所有的文件存档 最后检查最后检查 下面是另一个建议. 对于任何包装设计方案来说在完成以上10法以后, 再次检查你的设计如重要列表考虑如下：. 通过这样做减少在运输开始的发生意外的可能性. 包装设计方案清单包装设计方案清单 你要做的: 1. 考虑包装方面固体的浪费 和单位的装载量, 和他们的可选择性, 对于环境的最小影响? 最后检查最后检查2. 考虑可退回或可再利用的集装箱和垫片的使用? 3. 在运输循环中所有预期的花费因素：操作，存储，运输？4. 公司相似产品的包装花费的对比? 5. 考虑在材料和方法中所有可能的选择性? 6. 是否尽可能的使用了工业材料的标准

9、和设计标准? 7. 性能测试的设计与公认的行业标准? 8.记录了使用该公司的规范系统的设计吗？9.是否检查这条产品线的损伤和客户投诉? 10.是否满足各项规章制度，是否适用于该产品预计将遇到所有的分销模式呢？ 仓库仓库 对于特定的商品和特定的商品销售链来说，配送仓库是一个中央收集点.直到接到客户订单否则成品将被放置与仓库中。仓库的环境不被很多托运人员理解.一个典型的干杂货仓库可以包含20,000个独立的仓库间，一个金属制品的供应链仓库含有40000个独立的仓储间，产品在散装或整体包装后放在中心仓库中，根据仓库的需要被重新组合。选择性仓储是根据特定的店或目的地来选择独立的仓储，中心仓库为客户提供

10、了空间，在一些情况下. 一个或两个仓库会为整个国家准备. 仓库仓库 l 一个产品要适合仓库材料的操作系统，这通常指从非标准托盘松散堆放的负载或重新堆放的负载，这主要取决于操作. 产品送到仓库时其中33%到70%的产品在被存储之前要通过人工进行处理.,除了考虑到花费，跌落也是损坏的主要来源. 在挑选通道时，在每边存货要是容易辨别的。多彩色图形显示的是隐藏的重要信息.一个标有“金三角农场” A box labeled Golden Triangle Farms does not inform the stock-picker of the contents. Containers should b

11、e strong enough to be dragged off the pallet by one end, and stiff enough that they dont distort and release their contents when handled in less than ideal fashion. Glue flaps must have enough adhesive to resist abusive handling. The Warehouse An assembled order may contain items as disparate as eig

12、ht mirrors, six assorted clocks, a case of oil, four shock absorbers, a stepladder, and a Mepps #4 fishing lure. These and other items are assembled on a mixed pallet for transport to the retail outlet. Containers must be easily handled by the picker and should be readily packed onto a mixed-order p

13、allet. Container orientation on mixed-load pallets will tend to be on a best fit basis, regardless of This side up and Do not stack labels. It may be possible to pack a trapezoidal container efficiently on your pallet, but odd shapes do not pack well in a mixed-product pallet load. Use boxes with a

14、rectangular cross section wherever possible. 单位装载单位装载 托盘托盘 移动1000千克的load要比移动1千克的load要容易.load是最常用的单元式托盘，a platform that can be picked up by the tines of a forklift truck. Another technique uses slip sheets, tough fiberboard or plastic sheets on which the load is stacked. The truck used with slip shee

15、ts has a clamp mechanism that grasps a protruding edge of the sheet and pulls the sheet and load onto a platform attached to the truck. A third method of handling a large group of assembled objects is with a clamp truck, a mechanism that picks up loads by exerting pressure from both sides of the loa

16、d. Unit Loads Each method has its advantages and disadvantages. Slip sheetsare economical, take up little space, and are light. However, the equipment is not universally available, is more expensive, and is slower to operate. Pallets are universally adaptable to a variety of handling situations and

17、locations. However, pallets are costly, take up space, and can be difficult to dispose of. Clamp trucks use no added materials, but the geometry and character of the load must be such that it can be squeezed between the trucks clamps. Most pallets are made of wood, and choice of wood species has a g

18、reat impact on cost and durability. The denser and stiffer the wood, the greater the pallets durability and usually the greater its cost. Well-made hardwood pallets are the most durable and cost-effective option of the many material choices available. Other materials are usually selected for conside

19、rations other than durability. Unit Loads There are many possible pallet sizes and designs; however, for the sake of standardized distribution, certain sizes and designs predominate. By convention, a pallets size is stated length first, with length defined as the top dimension along the stringer or

20、stringer board ( Figure 16.3). About a third of all pallets are nominally 40 by 48 inches, the standard set by members of the Grocery Manufacturers of America. This size is also very close to the international 1,000 by 1,200 mm size. The two broad categories of pallet design are stringer and block t

21、ypes (Figure 16.3). A range of variations is available within each design type: Unit Loads Figure 16.3 A block pallet(left) and a stringer-type pallet(right) Unit Loads Reversible pallets have similar top and bottom decks. Nonreversible designs have different top and bottom decks, with only the top

22、deck designed to be a load-carrying platform. Wing pallets have the stringers inset so that the deck boards overhang. This allows for the pallets to be handled by slings. Pallets can be single wing or double wing, depending on whether one or both decks overhang the stringers. Two-way-entry pallets h

23、ave solid stringers and can be entered only from the two ends. Block-type pallets are four-way entry, since any equipment can enter the pallet from all four directions. A partial four-way has notches cut into the stringer bottoms. A forklifts tines can enter from any direction, but a hand truck can

24、only enter from two directions. Unit Loads In addition to providing a product platform, the pallet is a buffer against the handling environment. A forklift driver placing a pallet into position cannot see the exact placement location: he stops when he hits something. Viewed in this context, practice

25、s such as deliberate pallet perimeter overhang can only lead to problems, and warehouse operators condemn this habit. The Food Marketing Institute holds pallet issues responsible for about half of all observed damage and cites poor pallet footprint as the single largest cause of shipping damage. Of

26、this damage, 50% is attributed to poor pallet stability and 35% is attributed to pallet overhang. Pallet maintenance programs are essential. A common and easily remedied problem is fasteners working their way out of the wood. Unit Loads Unit Load Efficiency Warehouse floor space is rented by area, a

27、nd the more product that can be put into that area, the better. Trucks loaded with light product should have the available volume completely filled to carry the maximum amount of product per trip. Area and cube utilization should be every packagers concern. Optimum area and cube utilization begins w

28、ith the design of the primary package. Primary dimensions should be considered in terms of possible packing orientations in the shipping container, impact on corrugated board use in the shipping container, and palleting pattern and space utilization. Unit Loads “Arrangement” refers to packing patter

29、ns used when placing primary packages into a shipper. Traditionally, the problem was solved through intuition, experience, and a few nominal calculations. However, small cartons, packed 24 to a shipper, may have over a thousand possible orientation and palleting solutions. Computer arrangement progr

30、ams are available that will calculate all the implications of size decisions in minutes. Typical input data for a palleting-efficiency computer program are : Data pertaining to the primary container Allowed primary design changes, if required Data pertaining to the proposed shipping case Data pertai

31、ning to palleting requirements Unit Loads Typical output data for such a program might provide the following information: Optimum dimensions for the primary container Optimum packing orientations for selected primary containers Inside and outside case dimensions for each selected case type Number of

32、 units per pallet for each primary/case option Area and cube utilization for each primary/case option Recommended pallet patterns, including walk-around views Dimensional details of the pallet pattern Material areas used in primary, divider, and case construction Relative cost factors for each const

33、ruction Relative compression values for corrugated board constructions Proposed maximum warehouse stacking heights Unit Loads A thorough system analysis (including losses) can lead to substantial savings. A major business equipment manufacturer found that it had poor shipping experience because of t

34、he hundreds of different package sizes in the product line. The company designed a modular system, and all products were designed to fit one of 17 standard box sizes. Besides significant inventory reduction, the company gained substantial transport savings, since larger, more stable pallet loads cou

35、ld be built with the modular system. More-secure pallet loads resulted in further savings through reduced product damage. Unit Loads Stabilizing Unit Loads Unit loads often need to be stabilized in order to retain load geometry and order during shipping and handling. Strapping is used mostly for hea

36、vier goods. Care must be taken that strapping does not cut into the corrugated container, impairing strength qualities. Cord is sometimes used as a more economical alternative, also causing cut-in problems. Corner guards should be used to prevent cut-in where strapping or cord is the necessary choic

37、e. Shrink-wrapping is rarely used for load unitizing due to high installation and energy costs. Todays material of choice is stretch-wrapping. A good stretch-wrap application consists of two overlapped wraps extending 50 mm down the pallet to bind the load to the pallet. The wraps should overlap about 40% up the pallet side. Three overlapping wraps extending 50 mm past the top of the