1. Estar Wide Format Shipping Container RIT MSD I PRELIMINARY DESIGN REVIEW RIT MSD Team: Thomas Benner Brandon Kilbury Phillip C. McKee Justin Mintz Jason Ryan

2.  Project Summary  Key Requirements  Engineering Specifications  Functional Decomposition  Workflow and container concept development  Workflow and container concept selection  System Architecture  Present container concepts  Detailed design schedule & team concerns PRESENTATION OUTLINE

3.  Primary Task: Standardize pack to ship process for “new business” Estar products via: -Proprietary shipping container -Waste reduction in current pack to ship workflows  Secondary Tasks: -Provide ergonomic optimization -Quantify savings and future performance PROJECT SUMMARY

4.  Container must be compatible with current core and varying roll diameters and widths.  Unit cost ≤ $120  Container must last for at least 5 uses.  Must protect roll structurally (vibration and impact) as well as from contaminates (dirt and oil).  Throughput at windup ≤ 5 minutes  Total pack to throughput ≤ 10 minutes KEY REQUIREMENTS

5.  Must conform to all international shipping standards.  Container must meet or surpass current shipping capacity  dimensions and stackable.  Enable 4 way access for fork truck.  Container must be quick and easy to assemble/disassemble  safe and ergonomic. KEY REQUIREMENTS

6. ENGINEERING SPECIFICATIONS DescriptionRequired ValuesUnits Possible Additional Considerations Core Outer Diameter7Inches9" for Dryview Core Length58Inches Roll Diameter12 - 27.5InchesOne roll has 32" dia Roll Width47 - 56Inches Roll Weight500 - 1900PoundsRoll weighs 2600 lb. Overall Container Width29.5Inches Overall Container Length64Inches

7. ENGINEERING SPECIFICATIONS DescriptionRequired ValuesUnits Possible Additional Considerations Overall Container Height35Inches Container Re-Useability> 5Uses Container Impact Resistance10G Container Stack Height1 - 2Containers Container Cost120Dollars Container Component Lead Time < 4Weeks Packing Time in Windup Area<5Minutes Total Packaging Time< 10Minutes # of Operators Needed to Package 2Operators

8. FUNCTIONAL DECOMPOSITION

9. The Pack to Ship process must be considered before addressing the physical deliverable, much like design for manufacturing. This enables the MSD team to:  Ensure adequate waste reduction in current processes  Optimize the current manufacturing area layout & resources  Maximize the likelihood of the container and its assembly integrating well with existing resources in bldg. 317 and 318  Meeting throughput requirements CONCEPT DEVELOPMENT PROCESS

10. WORKFLOW CONCEPT DEVELOPMENT Pack to Ship workflow conceptualizationScore and rank workflows Select optimal workflows to pursueRevise workflows per market constraints

11. CONTAINER CONCEPT DEVELOPMENT Subassembly conceptualizationScore and rank complete concepts Select container concepts to begin design

12. SUBASSEMBLY DEVELOPMENT PROCESS Revise optimal workflow Revise concept to facilitate workflow Check feasibility of concept

13. PACK TO SHIP WORKFLOW CONCEPTUALIZATION

14. WORKFLOW SCORING VIA PUGH MATRIX

15. REFINED WORKFLOW SCORING

16. WEIGHTED RANKING & SELECTION

17. REVISED WORKFLOWS PER MARKET

18. CONCEPT FUNCTIONS & COMPONENTS

19. CONTAINER CONCEPT SELECTION

20. CONTAINER CONCEPT SCORING

21. SYSTEM ARCHITECTURE

22. CONCEPT ‘D’

23. CONCEPT ‘D’ - BASE

24. CONCEPT ‘D’ - SADDLES

25. CONCEPT ‘D’ - ROLL

26. CONCEPT ‘D’ - END BOARDS

27. CONCEPT ‘D’ - END BOARD SUPPORTS

28. CONCEPT ‘D’ - LID

29. CONCEPT ‘D’ – DOUBLE STACK

30. CONCEPT ‘D’ – OPTIMAL CONCEPT

31. CONCEPT “C-G” VARIANT

36. Task NameDurationStartFinish Choose concept for detailed design 1 dayFri 1/18/13 Finalize concept assembly5 daysMon 1/21/13Fri 1/25/13 Determine hardware and materials 5 daysMon 1/28/13Fri 2/1/13 Engineering Analysis5 daysMon 1/28/13Fri 2/1/13 Finalize detailed concepts5 daysMon 2/4/13Fri 2/8/13 Draft test plan5 daysMon 2/4/13Fri 2/8/13 Prepare for prototyping5 daysMon 2/11/13Fri 2/15/13 Detailed design review1 dayFri 2/15/13 DETAILED DESIGN SCHEDULE

37.  Straps?  Total prototype and testing budget?  Wood shop lead time and cost?  Packaging lab rules (scheduling, cost)  Customer approval issues, wrapping procedures, etc. who has final approval power?  Need to video current process  Throughput data at windup and for packaging, approximate annual overtime in 318 (hours, # rolls, and cost)  Safety and ergonomic concerns? Areas to focus on? TEAM CONCERNS