Estar Wide Roll Shipping Container

1. P13721 2012-2 – 2012-3 Kodak – Customer/Sponsor Steve Possanza - Guide Phil McKee – Tom Benner – Brandon Kilbury – Jason Ryan – Justin Mintz Problem Statement The motivation for the project is to standardize pack to ship processes for all of Kodak’s “new business” polyester film base products and reduce the frequency of damaging products during pack to ship. The primary task is to develop a universal shipping container to facilitate transportation and international shipment for all “new business” wide roll products that is robust, reusable, and cost effective. Development of the container should also facilitate standardization of pack to shipping processes as well as waste reduction in appropriate work groups. • Product Requirements • Modular saddles • Within 29.5 x 64 x 35 in. footprint • Endure 10G impact and vibration tests • Facilitates double stacking • Time in windup <5 min & total package time <10 • Does not require lifting w/ C hook • Reusable at least 5 times • Cost <$120 • Accepts a 27.5” dia. roll weighing 1700 lb • Streamline and standardize pack & ship workflow • Meet ergonomic standards • Protect from dust/dirt Current E3 Package Concept Selection Concept selection was made with regard to several selection criteria including container adjustability implementation, cost, time to package individual container, ease of implementing support, complexity, collapsibility for reuse, weight, and ability to prevent telescoping. Several different concepts were considered for the end design these different criteria were weighed to assist in concept selection. The final concept selected was based off of several iterations of concept improvement and then the concept that achieved the selection criteria most effectively was chosen as the final concept. Estar Wide Roll Shipping Container Functional Decomposition Additional Concept Ideas First Prototype Second Prototype Final Prototype Testing The testing that was conducted on the package in order to simulate the abuse that it could potentially see over its life cycle. In order to represent the worst case real scenario in the preliminary design, a single package was loaded with an overweight roll and fully strapped. This setup was then moved at full speed before colliding head-on with a rigid steel bumper. The attached accelerometer recorded over 13G’s and only minor cracks were seen on the initial test. Subsequent off center impacts aimed at the corner yielded similar results and the package did not fail. The final design will be tested in the RIT Packaging Lab facility to determine the ability to withstand an impact of two stacked on top of each other as well as the ability for a single package to withstand vibrations that would occur during shipping. Analysis A finite element model of the packaged roll was created and multiple static analyses were run to determine optimal component dimensions for different materials. A 10g acceleration was applied to the model to simulate an impact. This approach proved to be conservative since a substantial amount of energy is absorbed by the package during impact, thus the roll will see less than 10g of acceleration. Certain components such as the core stops could be analyzed very simply and were excluded from the model. These results allowed us to choose materials and dimensions for our first prototype. Finite Element Analysis Using FEMap • Results/Conclusions • going forward, design revisions • The preliminary testing showed that the package is feasible as a replacement for Kodak’s current package • Future testing still needs to be completed in order to validate that the package will be safe for implementation into Kodak’s workflow • The final design does not meet the cost specification set by the customer future iterations of the project could focus on reducing costs • The cost will not be as much of a barrier if the recipients of the package are able to return packages for Kodak’s reuse • The package also allows Kodak to implement a fast and lean workflow that will cut back on overtime expenses Sample Accelerometer Data From Testing • Acknowledgements • Kodak • Marshall Boxes • Steve Possanza • Marci Snider, Bob Huurman, Fred Demmans • Ed Emmerich • Mark Campbell