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Example #5 - Shipping Computer Monitors

Guacuco Computers, Inc.* will start shipping their brand-new Shell-shaped 15" monitor to their wide range of customers throughout the world. Given the intense competition in the computer monitor industry, Guacuco figures that they could try to save some shipping costs by optimizing their pallets throughout the various warehouses by where the product travels. The monitors are built somewhere in East Asia where the maximum allowable height is 1.45 meters (57 inches) including the pallet, they are stored in the Americas warehouse where the maximum height is 2.20 meters (87 inches) and in the European warehouse where the maximum height is 1.20 meters (47 inches).

The following describes how Quick Pallet Maker can find the box that will save shipping costs (by allowing more boxes per pallet) on different allowable pallet heights. This only works with QPM 1.0.4 and above (downloadable at this site). The Operating System for this example uses commas (,) to separate decimals (although this can be changed in the "Numbers" Control Panel).

Input Data

  • Package Shape: Rectangular (monitor) - select Rectangle from the Pull-Down menu.
  • Units: cm - Select cm/kg from the Tools menu
  • Monitor Length: 41 cm - type "41"
  • Monitor Width: 37 cm - type "37"
  • Monitor Height: 37 cm - type"37"
  • In this case, Only the height and length are allowed to be vertical to protect the monitor innards during transportation.
  • Monitor Weight: 10 kg. - type "10"
  • Case Count: 1 - type "1"
  • Board Thickness: 275-350# C Flute - Select from the Pull-Down menu and the values will update automatically.
  • Construction: RSC-Regular Slotted Container - default
  • Partitions: Square Liner - Choose Square Liner and Input a width and length addition of 1 cm, which would simulate a minimum styrofoam padding of 0,5 cm per side.
  • Minimum and maximum case dimensions: Use default values
  • Minimum and maximum case ratios: Use default values
  • Shipping Pallet Dimensions: Europallet 120x100x14,5 mm - select EuroPallet 1200x1000 from the Pull-Down menu.
  • Default values for the rest of the load restrictions.
  • Maximum Load Weight: 1500 kg (1,5 Metric Tons), which is approximately the maximum weight a Forklift truck can carry. - Default value

The input window should look something like this. Note that commas (,) separate the decimals.

The dividers window will look like this:

Given that the Maximum Pallet Height is variable, the user selects the Advanced Input Options from the Tools menu or presses the Ctrl+Alt+I (Command+Option+I for the Mac OS) keyboard shortcut. Once the data is filled in, the Advanced Input window should look like this:

The user will vary the Maximum Load Height between the 120 cm (European warehouse) and 220 cm (Americas warehouse) and will look for the highest possible value for cases per pallet. The latter option is not so important as the user will choose to view all the results instead of just the best one. If the user would have chosen to view only one result, then Quick Pallet Maker would have displayed the pallet for the maximum height only (220 cm). The number of iterations has been increased to 100 by pushing the slider to the rightmost position so that the minimum step of 1 cm is used. The criteria for number of iterations depends mostly on the computer speed; the faster the speed, the more amount of iterations (and a smaller step) can be made in the same time. In essence, if you have a top-of-the-line computer, don't doubt on going full steam ahead.

Once the OK button is pressed, the iteration window will appear and once the program's done iterating, the user will be presented with a solutions window that should look like this.

When the user discloses the rest of the window, it should look like the following drawing.

What Quick Pallet Maker did was to create 3 boxes by turning the monitor around within the box. The program calculated the amount of cases that would fit within the Pallet Height limitations and copied the results onto the table above. The 606 results were then analyzed by case type and the case type with the highest average Cases per Pallet was displayed (case #3). The value of 17,43 indicates that on average (between the minimum and maximum allowable Load Heights), the case type #3 will fit 17,43 cases per shipping pallet. These results can be copied onto a spreadsheet to make a graph if the user wishes. To display the case type #3, the user double clicks the line with the maximum height of 220 cm. The solutions window is displayed and should look like this:

The reason why case #3 produced a higher average cases per pallet was that it was a lower box (39 cm vs. 43 for cases #1 and #2) and every increment in Maximum Allowable pallet height would benefit a shorter layer. The next step is for the user to expand the box in order to add internal padding for the monitor and stability for the load. The pallet #6 was chosen since it has the highest amount of cases per pallet (30). The results table should look like this. Please note the added slack to achieve round numbers.

The next thing to do would be to generate drawings for each one of the different allowable pallet heights (120 cm, 145 cm and 220 cm). Please note that the Code number 2 indicates that the boxes are organized as the Box Length in the Pallet Width and the Box Width in the Pallet Length. The three drawings would look like this.

European Warehouse Pallet (max. height = 120 cm) Asian Warehouse Pallet (max. height = 145 cm) Americas Warehouse Pallet (max. height = 220 cm)

The packaging designer can generate three different reports to send to the Guacuco Computers Inc. warehouses around the world for palletizing instructions. These reports would be ready for exporting to a graphics file format or for printing.

* Imaginary Name

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