Chapter 5 Protective Packaging and Materials HandlingLearning ObjectivesProtective Packaging and Materials HandlingProduct CharacteristicsFigure 5-1: Portion of fabric care label for Levi’s jeans sold in JapanSlide 6Slide 7Packaging FundamentalsPromotional and Protective Functions of PackagingChecklist for Box Users (Figure 5-4)Slide 11Slide 12Slide 13Slide 14Figure 5-5: Boxmaker’s Certificate (BMC)Package Testing and MonitoringSlide 17Figure 5-8: Results of Compression TestSlide 19PackagingLabelingFigure 5-6: Examples of Shipping LabelsFigure 5-7: A handheld laser scanner scanning labels on a pallet load of product sitting in a warehouse rackIssues in PackagingSlide 25Identifying Packaging InefficienciesPackaging’s Influence on Transportation ConsiderationsFigure 5-10: A Pallet Shredder designed to reduce the cubic volume of wooden pallets and crating so that they cost less to transportUnit Loads in Materials HandlingSlide 30Slide 31Slide 32Unit Loads in Material HandlingFigure 5-11: A Battery Powered Lift Truck Used for Stock PickingFigure 5-15: Various Types of Intermodal Surface ContainersMaterials HandlingMaterials Handling PrinciplesMaterials Handling EquipmentSlide 39Slide 40Slide 41Case 5-1 Let There Be Light Lamp Shade CompanySlide 43Slide 44Slide 45Chapter 5Protective Packaging and Materials HandlingLearning Objectives•To know how product features affect packaging and materials handling•To identify the functions performed by protective packaging•To analyze the utilization of unit loads in materials handling•To appreciate how the environmental protection movement has affected packaging and package choice•To learn materials handling principles© 2008 Prentice Hall 5-2Protective Packaging and Materials Handling•Key Terms–Building-blocks concept–Closed-loop systems–Container–Cube out–Ergonomics–Materials handling–Package testing–Package testing–Packaging–Pallet (skid)•Key Terms–Part-to-picker system–Picker-to-part system–Shrink-wrap–Slip sheet–Unitization–Unit loads–Unit load devices–Weighing out© 2008 Prentice Hall 5-3Product Characteristics•Physical Characteristics–Density of bulk materials–Ability to withstand exposure to elements–Respiration•Chemical Characteristics–Incompatible products–Products requiring chemicals•Characteristics must be made known to consumers© 2008 Prentice Hall 5-4Figure 5-1: Portion of fabric care label for Levi’s jeans sold in Japan© 2008 Prentice Hall 5-5Product Characteristics•Hazardous Cargo–Explosives–Compressed gases–Flammable liquids–Oxidizers–Poisons–Radioactive materials–Corrosive materials© 2008 Prentice Hall 5-6Product Characteristics•Environmental Protection–Reduce packing materials used–Use packaging materials that are more environmentally friendly with recycled content–Use reusable containers–Retain or support services that collect used packaging and recycle it•Pallet shredder© 2008 Prentice Hall 5-7Packaging Fundamentals•Building-blocks concept–Smallest unit is consumer package–Each unit is stocked within the next larger one to protect the product•Packaging –refers to materials used for the containment, protection, handling, delivery, and presentation of goods–Serves three general functions•To promote•To protect•To identify (label) the relevant productPromotional and Protective Functions of Packaging•Protective functions of packaging–Enclose materials–Restrain materials from undesired movement–Separate contents to prevent undesired contact–Cushion contents from outside vibrations and shocks–Support the weight of identical containers stacked above–Position the contents to provide maximum protection–Provide for uniform weight distribution–Provide exterior surface for labeling–Be tamperproof–Be safe for consumers or others© Pearson Education, Inc. publishing as Prentice Hall11-9Checklist for Box Users(Figure 5-4)YOUR PRODUCT1. Have you given your box maker a description of your product and its use, the exact dimensions, weight and physical characteristics? 2. Is the product likely to settle or shift? 3. Is it perishable, fragile, or hazardous in any way? 4. Will it need extra protection against vibration, impact, moisture, air, heat or cold? 5. Will it be shipped fully assembled? 6. Will more than one unit be packed in a box? 7. Will accessories, parts or literature be included with the product? 8. Have you provided your box maker with a complete sample of your product as it will be packed? 5-10Checklist for Box Users(Figure 5-4)YOUR PACKING OPERATION1. Is your box inventory adequately geared to re-order lead time? 2. Is your box inventory arranged to efficiently feed your packing lines? 3. Is your inventory of boxes properly stored?4. Will you be setting up the boxes on automatic equipment? (lf so, what type? Size? Method of closure?)5. Will your product be packed automatically? (lf so, with what type of equipment?)6. lf more than one unit or part goes into each box, have you determined the sequence?7. Will inner packing — shells, liners, pads, partitions—be inserted by hand?8. Is your closure system—tape, stiches, glue—compatible with the box, packing line speed, customer needs and recycling considerations?9. Will the box be imprinted or labeled? 10.Will a master pack be used for a multiple of boxes to maintain cleanliness or appearance?Checklist for Box Users(Figure 5-4)YOUR STORAGE1. Have you determined the gross weight of the filled box?2. Does the product itself help support weight in stacking?3. Will the bottom box have to support the full weight in warehouse stacking? 4. Will boxes be handled by lift trucks which use clamps, finger lifts or special attachments? 5. Will filled boxes be palletized? (The size of pallet and pallet pattern may justify a change in box design or dimensions, if only to reduce or eliminate overhang.) 6. Would a change in box style or size make more efficient use of warehouse space? 7. Will filled boxes be subject to unusual conditions during storage—high humidity, extreme temperatures. etc.? 8. Is the product likely to be stored outdoors at anytime during its distribution?9. Would color coding simplify identification of various packed products?Checklist for Box Users(Figure 5-4)YOUR SHIPPING1. Have you reviewed the appropriate rules of the transportation service you intend to use (rail, truck, air, parcel post, etc.)? 2. Is your container
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