P20620: WindowSkin Primary Packaging

Problem Definition

Table of Contents

Team Vision for Problem Definition Phase

During the Problem Definition phase of Multidisciplinary Senior Design 1, our team wanted to develop an understanding of the problem WexEnergy has with packaging their product, the WindowSkin. We also wanted to determine which of the desired solution characteristics are non-negotiable and which fall lower on the priority scale. This ultimately resulted in two lists of requirements. The first is more qualitative and titled "Customer Requirements." The second is called "Engineering Requirements" and includes values to define what qualifies as satisfying the requirement. Something that was not originally a major objective during this phase was developing a better understanding of the WindowSkin itself. Once we met with customer we realized we had made some assumptions about the product that were incorrect so we took notes during the customer meeting noting the components we were not expecting and their terminology.

Project Summary

WexEnergy LLC manufactures a product known as WindowSkin™ that takes a single pane window to double pane energy efficiency and a double pane window to triple pane window efficiency. The WindowSkin is easy to install, nearly invisible, featherweight, and very affordable. Each WindowSkin is customized to fit its own window. To accommodate the variable widths and heights of their products, WexEnergy has used different box sizes for every individual order. Approximately 10-12 WindowSkins were packaged per box, with varying lengths and widths between 6" and 58". The WindowSkin is also very sensitive near the corners and can become damaged if not packaged properly. Transportation issues have caused the corners to break or become damaged during transit. In the past, WexEnergy has employed the use of custom corrugated pieces to protect the corners of their product. Along with the corners of the WindowSkins, whenever larger orders have been packaged they have been known to sag causing deformation to the product. WexEnergy has previously used custom corrugated cartons on orders that exceeded 50 WindowSkins to help mitigate this.

The goals of this project are to design a packaging solution that protects the product, is interchangeable with the variety of orders, upholds WexEnergy standards, and overall improves on the current packaging solution. Due to the uniqueness of each order, the packaging needs to be versatile enough to work with any order, regardless of dimensions. The solution needs to account for how sensitive the corners are and protect them appropriately. When numerous WindowSkins are packaged together, something will need to be in place to prevent sagging and deformations. WexEnergy has requirements regarding the cost of the packaging being less than current. The time to package the material also needs to be less than their current pack time. To continue with their sustainable mindset, the materials used to package the WindowSkins needs to be either recyclable or reusable. WexEnergy also has requirements in regards to the customer experience. The packaging will need to easy for one person to handle, as the companies installing them may not have equipment to handle larger loads. Some customers have minimal space to maneuver the packaging, therefore it needs to be sized appropriately to fit up stairwells or in smaller elevators. The components used to package the WindowSkins should be minimal so that the customer does not have much cleanup required after unboxing. Along with those, the packaging should also reflect upon the high quality of the WexEnergy product inside.

Use Cases


Objective: Package 10-12 WindowSkins as quickly as possible without damaging them

  1. Obtain all appropriate packaging components quickly and easily
  2. Assemble packaging components
  3. Insert first WindowSkin of that size
  4. Repeat up to 11 times
  5. Insert additional packaging components
  6. Seal packaging quickly and easily
  7. Palletize packages

Shipping Employee

Objective: Fill truck quickly without damaging products

  1. Receive pallets; some full, some not
  2. Loads pallets into truck, potentially stacking pallets on top of each other
  3. Loads pallets from other shipping customers until truck is full
  4. Offloads pallets at destination

Product Recipient

Objective: Open package easily without hurting self or damaging product

  1. Move package from drop off/receiving area to installation destination
  2. Open package
  3. Withdrawal product(s)
  4. Install product
  5. Dispose of packaging quickly and easily

Project Goals and Key Deliverables

Our goal by May 2020 is to provide a packaging solution that meets all constraints and has been tested on multiple occassions where the team has confidence in our product.

The key deliverable will be a physical box that can fit and secure multiple WindowSkins. On top of this week will provide design documents; this consists of conceptual and analytical findings along with drawings, a BOM and test results. To explain our process a poster and technical paper will also be included.

Customer Requirements (Needs)


The link to the live document is here

Engineering Requirements (Metrics & Specifications)


The link to the live document is here


The WindowSkin cannot be rolled.

It is recommended that WindowSkins be transported in a vertical orientation, not a horizontal orientation.

House of Quality


Design Review Materials

Include links to:

It is appropriate for you to send your customer and guide a link to this page in preparation for the review. This will ensure that they know what you will be presenting and how to view all of your work. Any EDGE link should start with http://edge.rit.edu/edge/P1xxxx..... Using "http" instead of "https" will ensure that non-RIT stakeholders can view the content without being prompted for a DCE login and password.

Plans for next phase

* Meet with WexEnergy supplier
*Develop packaging time standard
*Continue working with RIT packaging Science Department
*Finalize future testing standards to be implemented on final design
*Determine packing materials

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