TMNA Packaging Workshop · • Process: Thick wall structural foam (low pressure injection) molding • 4,000 lb. dynamic capacity • 30,000 lb. static capacity • Pallet weight:

February 4, 2020 / TMMTX

Packaging Workshop

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Property of ORBIS Corporation | www.orbiscorporation.com

Packaging Overview

• Packaging Overview – Container selection factors – QPC optimization within target container – Parts that require custom dunnage

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StakPak® System• 4 Generations in the family of StakPak® containers

• 27 models / sizes

• Weight capacity up to 40lbs.

• Smooth internal walls for ORBIShield dunnage installation

• Containers cube out standard AIAG pallets

• Material: HDPE– ESD / FR / Micro Fine Cell

• Manufacturing locations • Urbana, OH• Silao, Mexico• Osage City, KS

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StakPak Systems

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Benefits of StakPak Containers• Ergonomics/Safety

– Sprains, strains, lacerations

• Legislation on recycling and recyclable materials

• Eliminates corrugated packaging costs– corrugated setup costs– disposal of corrugated or

expendables– reduces logistics costs– packaging quality

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StakPak Features

• Drain holes in bumper and handles– prevent water from collecting in pocket areas and

in bumper– allows container to dry faster after washing– saves water in washers that recycle the water

• Continuous bumper– keeps dust and dirt from contaminating product

inside– acts as lid for container below

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StakPak Features (cont.)

• Detached Lids• Attached Lids

– Plastic hinge elements for 100% recyclability– Easy to repair/replace in the field

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StakPak Container Versions

RContainers: NSO (left), NXO

(right) and long boxesWhen used: cross stack apps –

higher weight loads –conveyors

REMEMBER: ID is reduced by ½” – cannot stack on any lids

MContainers: NSO, NXOWhen used: General applicationsNoise reduction when rolling on

a conveyor

SContainers: SOWhen used: when need

a little more durable bottom – may work better with some conveyors

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StakPak Options• StakPaks are available with:

– Hotstamps– Textured Surface– Cardholders– Labels– Label placards– Sequential numbers– Handles– Routered bottoms– Drain holes

• Standard stocked colors are:– Grey, Royal Blue, Med Green– All other colors there will be

color set-up charge.

• Non-Standard colors are available. Set up charges and additional costs apply

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Folding ContainersConductive & Static Dissipative• Conductive

– Materials have a surface resistance of < 10⁴ Ohms.

– Quickly displaces the charge, helping to protect direct discharges from reaching sensitive products.

• Static dissipative – Materials have a surface resistance of ≥10⁴

to <10¹¹ Ohms. – Displaces charge slower than conductive

materials. – Dissipative materials help protect against

charged device model (CDM) damage. – Sensitive device or circuit board becomes

charged, dissipative material will slowly control the discharge to protect the product.

CONFIDENTIAL Copyright©2019 ORBIS

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Folding ContainersESD Protective SolutionsConductive:

• Injection Molded – StakPak® Straight wall containers– LEWISBin+® Storage containers

• Thermoform – 45x48-2 MI Pallet

• ORBIShield® Plastic Corrugated– Dunnage– Sheet– Containers

CONFIDENTIAL Copyright©2019 ORBIS

Static Dissipative: • Injection Molded

– StakPak® Straight wall containers• Compression Molded

– LEWISBin+® Plexton® Heavy Duty Trays

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StakPak® Cut-N-Weld™• Add length, width or height to an existing injection-molded StakPak to

create a durable, returnable container to fit your specific application.

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StakPak Cut-N-Weld

• Optional hand holes with or without plastic handle inserts• Ergonomic pocket handles for comfort and safety.• Hot stamping, cardholders and label placards available. Has

protected exterior space for customer identification.• Identification options include molded-in logo, hot stamp and

cardholders• Compatibility with select extended ORBIS thermoformed

pallets

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StakPak Systems

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Plastic Pallet Systems• AIAG and global footprints drive standardization

• Sizes: 45x48• 32x30 / 32x38 / 45x54 / 45x56 / 45x58 / 45x60 / 48x57 / 48x60 / 48x62• Metric also available

• Creates unit load efficiency (top frames, seat belt systems, etc.)• Simplifies inspection processes for international shipments• Optimizes transportation

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StakPak Weight Loads

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Pallet Nestable Style:• SP484506-SF is TOYOTA Code

• 45x48 SFP Pallet Blk is ORBIS Code

• Process: Thick wall structural foam (low pressure injection) molding

• 4,000 lb. dynamic capacity

• 30,000 lb. static capacity

• Pallet weight: 37 lbs.

• Space savings in warehouse due to nesting when empty

• Lighter weight allows for more product weight on truck

• Options for hot stamp, labels (RFID)

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Top Cap Nestable Style:• SL484503 is TOYOTA Code

• 45x48 MP3 Topcap CISC Blk PE is ORBIS Code

• Process: High pressure injection molding

• Designed to interlock with the legs of nestable pallets and many bulk bases

• Broad compatibility accommodates maximum trailer efficiency

• Compatible with StakPak and Hand Held Folding Containers

• Options: Vinyl labels, identification plates, hot stamps, seat belt buckles

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• BulkPak containers in the market– Sizes: 30x16, 32x30, 40x48, 48x45, 56x48, 62x48,

64x48, 65x48, 70x48, 78x48– Weight capacities up to 2,000 lbs.

• Fabrication options available• Manufacturing locations

– Bardstown, KY– Georgetown, KY– Urbana, OH– Menasha, WI– Silao, Mexico

Heights;25”34”50”

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53’ truckload capacity –208 collapsed bins 78 assembled bins, 26 positions

SK454834-4DL TOYOTA Code; 4 DoorSK454834-2D48H TOYOTA Code; 2 Door 48”

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HDMP Features and BenefitsWrap around geometry, more durable for stacking, compression, high impacts

Panel retention clips for easy panel removal. Safe and fast repair, no tools required.

53’ truckload – 252 collapsed bins per truckload, 28 positions

Robust two-piece spring loaded latches support safe handling

Many areas for identification

One piece molded-in perimeter stringer

Welded base plate –increase base strength

Corrugations in sidewalls –increase strength

Durable articulating door hinge allows for quick installation

SK454834-2D48 TOYOTA Code; 2 Door 48”Also available in 25” & 27” heights

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Right Sizing Opportunity• Conversion from inefficient

alternative packaging– Underutilized 3230 bulk– Steel/wire baskets– Expensive welded bulk

containers– Wooden crates– One way expendable packaging

• First molded half size 3230 container with ability to present short side to the assembly line.

Underutilized Example 3230

Right Sizing Example

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Design ComparisonThick Wall Part Design

“Structural Foam”• Strength: Best for high loads,

combines a resilient core with a hard surface

• Impact: Will “chunk” off plastic at high forces, maintains shape at low forces without deformation

• Weight: Best for heavy loads• Warp/Stress: Less warp, less

molded in stress• Standard Applications: Bulk Bins

& pallets

Thin Wall Part Design“High Pressure”

• Strength: Best for lower loads• Impact: Will “pierce” plastic at

high forces, deforms at lower forces

• Weight: Best for light loads• Warp/Stress: Increased warp,

molded in stress• Standard Applications:

Handheld Totes & Top Caps

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• OPTE MAX analyzes part math data and arranges products in the most efficient pattern & orientation

• This tool allows our engineers to quickly determine the optimal method for packaging simple to complex parts in standard or custom containers

• With the ability to deliver rapid results, our engineers are able to evaluate several options and deliver alternatives that work best for our customer’s supply chain

OPTE MAX

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Optimizing parts in containers

Uses part math data & we select from the library of standard containers to optimize cube utilization

• ORBIShield™ dunnage/part separation

• Pattern load• Random bulk load

OPTE MAX™

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Video Link!

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OPTE MAX™

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Video Link!

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OPTE MAX™

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Video Link!

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Property of ORBIS Corporation | www.orbiscorporationProperty of ORBIS Corporation | www.orbiscorporation.com

OPTE MAX™

• Standard report– Part information– Container type– Parts/container– Weights & dimensions

(metric)– 4 views

• Front

• Top

• Side

• Isometric

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Real-world application exercise

• An opportunity to go & see some actual packaging applications– Review current part packaging– How could it be done differently & why?

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ORBIS Custom Design Inputs

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Design Requirements

Materials

Pack Density

ORBIShield

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ORBIS Standard Materials

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ORBIS Standard Materials

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Standard Rigid MaterialsBlack Plastic Corrugate

• 2mm, 3mm, 4mm, 5mm, 6mm, 8mm & 10mm

• Can be laminated for Class A surface protection.

EFB 2H EFB SHD

HDPE TRI Laminate (Con-Pearl) Proluxe

• Shock absorbing properties and Class-A part protection

• Good for heavy parts• Lightweight foam

• Good for oily applications• Powertrain parts, gear

parts and metal rack dunnage

• Ideal for divider sets, solid plastic sheet that helps maximize cube utilization

• Ideal for use with washing systems

• Non-directional structure for improved strength over corrugated material

• Ideal for horizontal dividers in side-loading dunnage

• Can bend and flex: bridges gap between rigid and fabric divider sets

• Painted components • Chrome trim, headlamps and tail

lamps

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Standard Laminate MaterialsTYVEK Brushed Poly Spuntex

Edge ProtectionTYVEK Brushed PolyBlue Spuntex

• Protection for class A surfaces and other abrasion sensitive parts

• Requires a second structure support such as PVC



Softshield Sealed Edge

Microtex

• Protection for class A surfaces, similar to Evolon

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Standard Fabric MaterialsSoftshield

• Soft finish protects certain Class A surfaces, heat resistant dunnage bag, pouches and divider sets

PVC TYVEK

Clear PVC Brushed

• 13oz & 18oz• Protection for non class A

surfaces

Protection for Class A surfaces and other abrasion sensitive parts

• 13oz, 18oz, 30oz• Used as cover, curtain or back

sheet. • Allows to see though the insert

but still have protection

• Protection for Class A surfaces and other abrasion sensitive parts

• 15oz 1 side and 2 side

Propac

• Tri-laminated non-woven fabric

• Class A 2 sided• Ideal for top loading

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Standard Foam MaterialsXLPE Foam

• Non-abrasive with excellent shock/vibration protection

• Cushion Packing• Class A surface protection

1.7# Reclaim PE Foam

• Lightweight, low abrasive foam with good shock/vibration protection

• Foam pads

• Durable, resilient, low-abrasive with excellent shock protection

• Foam pads for heavier items

• Streamlined fabrication with one material and one mold. No assembly or finishing needed

• Some designs do not require totes• Parts with complex cavity shapes and contours• Electronic part protection

Molded EPP Foam

Custom Thermoforming

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Thermoforming Benefits• Durable, recyclable and returnable • Less expensive tooling than injection molding• More durable than foam and molded pulp• Optimize pack density

– Multiple layers in a tote/bulk container– Multiple parts per tray

• ORBIS value and one stop shop

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ORBIS Thin Gauge Thermoforming-Urbana, OH

• HIPS, ESD HIPS, HMWPE, and ABS up to - .125 gauge• Maximum of 5 inch draw

• PET Material up to .060 on the Lyle; 2.5 inches of draw• Maximum tray size of 30” x 66”• Reusable trays for totes & expendable trays

Thin gauge reusable tray Thin gauge reusable trays for a 32”x30” container

Thin gauge tray (High volume)

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ORBIS Thick Gauge Thermoforming- Menasha, WICapability to run a tray mold size up to 76” x 115”. • 45x48 Pallet for containers • Can form as thin as .100” and as thick as .400”. • HMWPE and HIPS materials are most commonly used• Single-sheet thermoform only• Minimal sample capabilities

.300 gauge tray for 4548 container .200 gauge tray for 2422 Tote

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Typical Uses

Air bags

Turbo, Inlet/Outlet tubes Brake Controllers- ESDCoil Springs

Door Handles Transmission Actuators

AdjustaPak

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Key Features• Easy & Safe Line Side Part Presentation

• Unique Rail System – Rust Resistant– East Sliding for Life of the Product

• Configurable Heights and Layers

• Reusability of modular system in different bins

Metal Solutions

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Metal Manufacturing Locations

Leon, Mexico Greenville, SCAverage 1,000 units per week*

Average 750 unitsper week*

In house Design and Prototype

In house Design and Prototype

Average lead time 6-8 weeks

Average lead time 6-8 weeks

*dependent on complexity and design of metal solution

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WIP with Stacking

Truss Base

Low Profile

ORBIS Metal Solutions

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Walk On48” x 96” w/ foam

Pin Pallet*MX only

Metal Bins*MX only

ORBIS Metal Solutions

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DunnageDisaster!• Original packaging

directive was to provide best protection for components

• Modified position once program packaging cost was tallied and compared to budget

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Tier One Seating Manufacturer

• Several parts to review– Side shield R1 R4– Recliner cover R1 R5– 2nd row shield R1 R5– Handle bezel R1 R5– 3rd row 60% cover R1 R4

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Side Shield - R1

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Side Shield - R4Reductions:• Basepad (foam)• U-Pad

construction (pcorr on the bottom)

• Lamination• Stitched Edging

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Recliner Cover – R1

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Recliner Cover – R5Changes:• Maximized number

of cells in container• Modified flute

direction for better yield

Reductions:• Reduced divider

height• Reduced lamination

to only lengthwise in cells

• Removed basepad(foam)

• Removed stitching

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2nd Row Shield – R1

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2nd Row Shield – R5Reductions:• Stitched Edging

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Handle Bezel – R1

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Handle Bezel – R5Reductions:• Reduced cell

height• Removed

stitching• R4 – tested

removing all lamination – had to add it back for R5

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3rd Row 60% Cover – R1

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3rd Row 60% Cover – R4Changes:• Reduced quantity

of cells – 2 parts per cell now

Reductions:• Removed

stitching• Removed

lamination• Removed

basepad (foam)

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Dunnage Materials Change Study

• The following exercise involved changing the materials used for a packaging project, not the structural design or the purchased quantity of packaging

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Dunnage Materials Selection

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Dunnage materials selection

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Property of ORBIS Corporation | www.orbiscorporationProperty of ORBIS Corporation | www.orbiscorporation.com

Packaging Applications • Headlamp• Tail Lamp• Fog Lamp Cover• Steering Wheel• HVAC• Starter Assembly• AC Compressor• Radio / Navi• Interior Trim• Side Door Glass• Radiator/Cooling Module• Mud Guard• Muffler• Window Regulator

• I/P Inner• Roof Rail• Front Wiper Assembly• Fuel & Brake Lines• Brake Booster• I/P Upper• Tonneau Cover• Grille Assembly• Wire Harness• Seat Belts• Trunk Floor Mat• Bumper Guard• Spoiler

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Headlamp Packaging

Material Handling - Benchmarking

Metal / Maximus Metal with TF Trays EPP Tote

Highlights:• Multi component dunnage

Highlights:• Single component dunnage• Line side savings in flow

rack system• System cost reduction• Trailer efficiencies

Highlights:• Two component dunnage• Cost reduction for high

volume projects

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Tail lamp Packaging


Metal / Maximus Metal with TF Trays EPP Tote / Tray

Highlights:• Multi component dunnage

Highlights:• Single component dunnage• Line side savings in flow

rack system• System cost reduction• Trailer efficiencies

Highlights:• Two component dunnage• Cost reduction for high

volume projects

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Fog Lamp Cover Packaging


Bulk Bin w/ Rigid Tote w/ Rigid Tote w/ Textile

Highlights:• Bulk Pak w/ Rigid: low cost solution utilizing tilt or turn table

to achieve ergonomic requirements

• Tote: preferred for JIT supply chain operations; increased pack efficiency when utilizing part nest

Rack or Bin w/ PC Tote

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Steering Wheel Packaging


Metal Tote w/ Rigid Bulk Bin w/ Rigid

Highlights:• Tote w/ Rigid: standard Toyota and Subaru (4) QPC tote

design

• AdjustaPak: ergonomic, cost and line side efficiencies

AdjustaPak

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Steering Wheel Packaging – 300K Annual Volume

Cost Savings Analysis

Tote w/ Rigid (Current) Bulk Bin w/ Rigid AdjustaPak

Highlights:

Footprint: 24x15x18Pack Density: 4Investment: $561KPKG $ / Unit: $9.4Logistics $ / Unit: $2.38

Highlights:


Year 1 Savings: $491K

Highlights:


Year 1 Savings: $502K

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HVAC Packaging


Metal w/ TF Tray Shelf Metal Solution Metal w/ EPP Tray

Highlights:• Rack w/ EPP Trays: gravity assist conveyance into line side

roller rack

• Clamshell: maximum part quality

Clamshell

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Starter Assembly Packaging


Thermoformed Tray Tote w/ Die Cut Foam

Highlights:• Low cost solution for high

volume applications• In-line, sequence, or sub-

assembly space available with 2nd X, Y for consumed

Highlights:• Preferred packaging for JIT

supply chain operations

EPP Tote

Highlights:• Vertical part nest

potentially increases parts per unit load and trailer efficiencies

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A/C Compressor Assembly Packaging


Metal w/ TF Tray Tote w/ Rigid Thermoformed Tray

Highlights:• Multi tier shelf rack

Highlights:• Cost reduction vs. rack if

line side space allows for one additional footprint

Highlights:• QPC of 2 achieved utilizing

a 16x15 tote footprint• QPC of 1 in 12x15 footprint• Small lot tote to support

line side flow rack system

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Radio / Navi Packaging


Bulk Bin w/ Rigid Tote w/ Rigid Tote w/ Die Cut Foam

Highlights:• Bulk Pak w/ Rigid: low cost solution utilizing line side tilt or

turn table to achieve ergonomic requirements• Tote: preferred for JIT supply chain operations; increased

pack efficiency when utilizing part nest• EPP Tote: low cost packaging solution vs. tote

EPP Tote

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Interior Trim Packaging


Bulk Bin w/ Rigid Metal w/ Textile OPTE Tote

Highlights:• Bulk Pak w/ Rigid: line

side tilt or turn table -ergonomics

• OPTE Tote: Collapsible for supply chain efficiencies

Tote w/ RigidRack or Bin w/ PC Totes

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Side Door Glass Packaging


Bulk Bin w/ Rigid Walk In Metal Solution

Highlights:• Total system cost reduction• 1.7:1 collapsible for

warehouse and outbound freight efficiencies

Highlights:• Common S/D glass

packaging

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Radiator Packaging


Bulk Bin w/ Rigid Metal

Highlights:• System cost reduction• Potential for collapsible

container for improved supply chain efficiencies

Highlights:• Line side presentation

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Mud Guard Packaging


Metal Bulk Bin

Highlights:• Line side presentation to

Associate / Operator

Highlights:• No interior dunnage• Improved supply chain

efficiencies – logistics and warehouse operations

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Muffler Packaging


Metal Bulk Bin Steel Bin

Highlights:• Parts immobilized to

ensure part quality

Highlights:• Cost reduction, non-chrome tipped mufflers

• Chrome tipped, add base pad w/ foam rails per layer

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Window Regulator Packaging


Tote Tote w/ Rigid Tote w/ Rigid

Highlights:• Tote w/ Rigid: Engineered cell design increases supply chain

efficiencies

• Rack / Maximus: improved manufacturing efficiencies for Tier-1 suppliers

Metal / Maximus

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I/P Inner Packaging


Metal Walk On Metal Metal w/ EPP Trays

Highlights:• Part contamination – dirt /

debris

Highlights:• Improved supply chain

efficiencies thru part nest in EPP trays

Highlights:• Walk in rack feature

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Roof Rail Packaging


Shelf Metal Solution Bin w/ TF Rails Metal w/ EPP Tray

Highlights:• Bin w/ TF Rails: low cost packaging option in high volume

part applications

• AdjustaPak: low cost packaging option with improved line side ergonomics

AdjustaPak

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Front Wiper Assembly Packaging


Metal / Maximus Tote w/ Rigid Thermoformed Tray

Highlights:• TF Trays: low cost option when additional line or sequencing

area footprint available for empty packaging return

• AdjustaPak: low cost option with improved line side ergonomics

AdjustaPak

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Brake Line Packaging


Metal Solution Steel Bin Cantilever Arm Metal Solution

Highlights:• Improved part load /

unload• No part to part tangle

Highlights:• Improved part load /

unload

Highlights:• Low cost option• Requires plastic bags to

minimize part to part tangle

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Brake Booster Packaging


Shelf Metal Solution Shelf Metal Solution Thermoformed Trays

Highlights: Highlights:• Low cost option when

additional line, sequencing or chassis area footprint available for empty packaging return

Highlights:• Improved load / unload

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I/P Upper Packaging


Metal or Maximus w/ Textile

Metal or Maximus w/ Rigid

AdjustaPak

Highlights:• Rack / Maximus: line side presentation; potential for in-line

sequencing

• AdjustaPak: reduced unit cost and packaging investment

Metal or Bin w/ PC Tote

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Tonneau Cover Packaging


Metal w/ Textile Metal w/ Rigid AdjustaPak

Highlights:• Line side presentation

Highlights:• Low cost option with

improved line side ergonomics

Highlights:• Reduced interior dunnage

cost vs. textile

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Grille Assembly Packaging


Metal / Maximus Metal or Bin w/ PC Totes Tote

Highlights:• Sequence to line side

operations

Highlights:• Preferred packaging for JIT

supply chain operations when part conveyed to production line

Highlights:• Reduced packaging spend

and packaging investment

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Wire Harness Packaging (MX to US)


Corrugated Tote OPTE Tote

Highlights:• Increased part piece price

– packaging / SGA

Highlights:• Total system cost reduction• Collapsible for supply chain

efficiencies - warehouse and logistics

Highlights:• Part piece price reduction -

expendable to returnable conversion

• Environmental sustainability

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Seat Belt Packaging


Tote w/ Rigid Tote w/ Textile Tote

Highlights:• Standard seat belt

packaging option

Highlights:• Expendable sleeve on

buckle• No dunnage opportunities

– seat belt type -> A vs. B Class

Highlights:• Improved part to part nest

in flexible dunnage

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Trunk Floor Mat Packaging


Bulk Bin Rack / Maximus

Highlights:• Class A to A, B to B for part

quality• System cost reduction• Supply chain efficiencies -

warehouse and logistics

Highlights:• Line side or sequence area

presentation and ergonomics

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Bumper Guard Packaging


Walk In Metal Maximus w/ Rigid AdjustaPak

Highlights:• Walk in rack

Highlights:Low cost option with improved line side ergonomics

Highlights:• Line side presentation • In-line sequencing

opportunity

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Spoiler Packaging


Metal Maximus w/ Rigid Metal w/ Textile

Highlights:• Walk in rack with foam

finger dunnage to improve part to part nest

Highlights:• Improved part to part nest

vs. rigid when spoiler has curvature

Highlights:• Line side presentation • In-line sequencing

opportunity

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Fabric OPTE Tote Returnable SystemsQuality:

• Packs utilize only the best fabrics, typically Tyvek, to come in contact with the part. (Brushed Poly/Headliner also good options)

• Each cell is designed to limit the movement in transit, thus reducing risk of damage

• Previous projects have shown a substantial reduction in quality issues compared to expendable packaging.

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OPTE Tote Returnable Systems continued…OPTE Tote Review:1. Our systems are designed to reduce shipping cost, improve quality, and

reduce handling and line side space needed. 2. Estimated savings show a pay off in year 1 and a total savings of

$1,639,941.35 over 5 years. Tier 1 conversion.

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ORBIS AdjustaPak– Fabric pouches• Modular design, easily engineered to be right sized to almost any Bulk Bin.• Stand alone assembly, does not need to be attached to the bulk bin, easily drops in, to

save time and reduce cost.

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Rack Solutions – EPP Trays

• EPP inserts molded to the part’s shape provides superior part holding capability.

• Combined with a collapsible rack provides 2:1 return ratio, and significant supply chain savings.

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Instrument Panel Rack cont’d

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Commodity:Fender Assembly

Container:HD4845-50 Single Entry Maximus w/ 6 “Dresser Drawers” & Protective Vinyl Curtain

Materials Used:4mm Blue Plastic Corrugated w/ Solid HDPE Drawer Rails (EFB-2H, Respironics solution)

Maximus Solutions – PCorr Trays (EFB-2H option)

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• Coating provides the toughest possible protection for heavy or sharp parts.

• Creates a flexible, extremely tough, monolithic membrane with excellent environmental protection against moisture, chemicals & acids.

• Virtually shave-proof; excellent for sharp parts that are sensitive to any shavings from the dunnage.

Maximus Solutions – Utilizing Polyurea Coatings

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• Sling bag style allows for vertical nesting, optimizes density.

• Angled horizontals allows for increased density in the width direction.

• Fabric hanging bags in general are more suited to nesting parts, and are usually the better choice for longer thinner parts.

Fabric Rack Solutions – Sling bag & Angled cells

Documents

TMNA Packaging Workshop · • Process: Thick wall structural foam (low pressure injection) molding • 4,000 lb. dynamic capacity • 30,000 lb. static capacity • Pallet weight: