P20620: WindowSkin Primary Packaging

Preliminary Detailed Design

Table of Contents

Team Vision for Preliminary Detailed Design Phase


Prototyping, Engineering Analysis, Simulation

Time Study Data


Avg Trial Time


Time to Insert 5 WindowSkins


live document.

Feasibility: Prototyping, Analysis, Simulation

Jamestown Shipper Options

Jamestown shipper options without required tooling are Regular Slotted Container (RSC) or Full Overlap (FOL).

Regular Slotted Container (RSC) is recommended by Jamestown, requires less material, and is cheaper. RSC will be used for all the propsed shipper sizes.

Full Overlap (FOL) is stronger from overlapping material and more expensive but the extra strength is not needed for the packaging. Because the extra strength is not needed, RSC boxes will be used as the shipper.

Packaging Solution Concepts:

Fold Over Concept


The fold over concept shown above helps protect the corner and edges. This concept also helps simplify the unpackaging process improving customer experience.

Bump Out Design


The bump out concept helps prevent sagging.

Drawings, Schematics, Flow Charts, Simulations


The proposed shipper sizes were selected from considering standard pallet sizes and looking at current WexEnergy order sizes. Four standard shipper sizes will accommodate all possible size WindowSkins. The sizes were optimized to best fit various WindowSkin sizes while easily packaging different proposed shipper sizes to fit on pallets. The shippers will be RSC boxes as explained above. Shipper size 1&2 can fit on a standard 48”x40” pallet and size 3&4 can fit on a custom 60”x40” pallet. The shippers will be made out of 32 ECT corrugated cardboard and the extra strength from the 44 ECT is not needed for the shipper.


The four standard size shippers can accommodate all possible size WindowSkins. The size range of WindowSkins is listed in the chart above.


Four different dividers will be made, one for each proposed shipper size. The chart above shows the required height and length of each divider for each standard shipper size. All dividers will be corrugated so that they are strong enough to protect the WindowSkins.

Bill of Material (BOM)

Bill of Materials


Test Plans


Design and Flowcharts

Sub-assembly Interface Diagram


Risk Assessment

During this phase, two new risks were added to the risk table and accompanying graph:

When comparing all of the risks we found two that were tied with the highest score, and are therefore the ones will shall try to mitigate the most:

For any supplementary information on the risks please see the associated live document with all risk data.


Design Review Materials

Presentation Handout: http://edge.rit.edu/edge/P20620/public/PDR%20Handout.pdf

Presentation: http://edge.rit.edu/edge/P20620/public/PDR%20Presentation.pdf?rev=0

Plans for next phase


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