P13721: Estar Wide Role Shipping Container
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Build, Test, Document

Build, Test, and Integrate

INITIAL TESTING

Initial testing of the first prototypes was completed at the Kodak site shipping dock. This involved assessing how each component integrated into the complete package and how well the film roll was supported. It was observed that a small gap existed between the Saddles and End boards. This gap was due to the inaccuracies in thickness of the plywood used; or possibly a measurement error made during fabrication. This gap allowed for excessive lateral movement of the saddles and the film roll while transporting with a pallet jack or fork truck.

Once the container was assembled impact testing was performed. Two different scenarios were chosen to simulate how the container could be damaged in the production environment: starting and stopping with a pallet jack and fork lift, and accelerating the container to make an impact with a bumper at the shipping dock. This method, however basic, would immediately show the week points of the current design. A USB accelerometer was used to measure the approximate g forces seen during start/stops and impacts. Standardized packaging tests involving controlled impact and vibration trials would be performed on future prototypes. The initial testing served to gauge which components would need to be thickened and which dimensions needed revision.

All of the Horseshoes with thicknesses greater than .75” proved to be too heavy for easy manipulation by operators. So although multiple sets of varying thickness Horseshoes were fabricated the team chose to further test the .75” thickness. This thickness was almost identical to the current end boards in use with the E3 package.

The .75” Horseshoe set withstood 15 impacts with an oversized 2200 lb. roll with no damage. So the .75” Horseshoes were chosen for the final prototype: they would be the cheapest to manufacture in terms of material, and since they withstood much more force than necessitated by the customer specification. Two failures were observed during testing after 3 trials: the roll fell from the saddles due to both limited surface area under the core and excessive play between the Saddles and End-boards. The distance between each saddle would be decreased and a thicker layer would be added to the triple ply Saddles. The thicker layer would lend more support to the roll core.

The End-boards were the only component that sustained damage during testing. It was decided that the final prototype would implement a thicker End-board to increase robustness. The 1/8” thicker End-board would also serve to limit the flexing observed due to movement of the Saddles while the container was starting and stopping during testing.

Initial prototype

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REVISED DESIGN

Further design revisions were made post-testing for the final prototype. Cut-outs were included in the Horseshoes and Core Stops to facilitate more ergonomic handling. Also, the initial prototypes used plastic based strapping to reinforce the Side and End-boards around the perimeter of the pallet base. The final prototype implemented steel straps stapled around the perimeter of the pallet base to further bolster the construction. This would help retain the roll should it fall from the Saddles during the pack for ship procedure prior to Horseshoe application and strapping. The steel bands would also aid in bolstering the pallet base during impacts.

Following the first vibration test it was found that the core and roll would need to be locked in position more securely along the y-axis. So the radius within the Horseshoe that surrounds the core was altered so Horseshoe placement locks the top of the core into the seat of the Saddle. The overall height of the package was reduced as well. The Saddles and Horseshoes would be reduced in height by 4” to lower the COG and prevent excessive movement or displacement of the Saddles and roll during package transport.

Single package - final prototype

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Single package - final prototype

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Single package - final prototype

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Double package - final prototype

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Double package - final prototype

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CONCLUSIONS AND RECOMMENDATIONS

Supplied design revisions should be accepted and sent to the vendor utilized during the project. With updated packages the standardized impact and vibration testing can be completed. To drive down container unit cost the design should be bid out to multiple vendors. Unit cost should not be the driving factor for container implementation.

Going forward the customers should look to grow business with customers that will buy in higher volumes. Higher volumes will make it more feasible for customers to return the containers economically. This will allow for multiple uses at and beyond specification. This is where some of the cost per container will be recuperated.

Also, the lean savings must be accurately quantified to ascertain the true benefit of the container being implemented. It is recommended to measure throughput improvements and lead time reduction should the container be used. Savings may also be had by reducing the finished goods demand buffer which is kept due to repacking rolls in the current manner. Implementing the leaner workflow associated with this container should allow for the elimination of that inventory.

Test Plans & Test Results

Prototype testing was conducting in a number of stages. Preliminary testing consisted of verifying that the package could support the max weight roll. Subsequent testing involved informal impact tests with forces measured using an accelerometer. The final verification testing includes a 10G impact and a double stacked vibrations test. The test plan is found here and shown below.

Preliminary testing was successful and showed that the package was able to accommodate the largest roll weight and with stand impacts of at least 13G. The first of the final verification tests to take place was the vibrations test. The package failed the vibrations test because both rolls fell off of the saddle. Root causes of failure were considered and design revision have been suggested.

Test Plan

Damaged Saddle post vibration test. Roll and core displaced from Saddle in the y-direction after 24 min. Remained pinned for duration of 3 hour test. public/Photo Gallery/damaged saddle.jpg

Damaged core and core plug --> may lead to using more rigid core and plug

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Same as above

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Standard Operating Procedure

1. Roll base with saddles and belly-wrap into wind-up area, ensuring wrap is contained in the base.

2. Place edge protection (foam) on ends of roll.

3. Line up base under roll, ensuring adequate saddle space for each side of the core to sit on.

4. Tape wrap to roll outside knurls.

5. Advance the roll to wrap, the belly wrap should overlap itself and be free of significant folds or bunches.

6. Tape across seam.

7. Lower roll ensuring edges of wrap hang outside the saddles and core is in contact with saddles on both sides.

8. Tuck excess wrap into core.

9. Insert core plugs.

10. Insert core stops.

11. Move to packaging cell.

12. Place horseshoes.

13. Install straps, 1 horizontal, 2 vertical, positioned in notches in horseshoes and base.

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