RIT MSD II Final review Estar Wide Format Shipping Container

1. RIT MSD IIFinal reviewEstar Wide Format Shipping Container Thomas Benner Brandon Kilbury Phillip C. McKee Justin Mintz Jason Ryan

2. MSD I Recap • Scope • Develop universal package to accommodate new products • Standardize pack-to-ship process • Overview • Gathered needs and specs • Concept development • Design selection • Engineering analysis • Detailed design

3. Impact Testing - results • Impact Tests performed at Kodak • 10-15 impacts • 2200 lb roll • Max acceleration of 13g measured at base of package • Translates to an acceleration of 2 for roll • First impact cracked the plywood saddle supports • Following impacts didn’t cause further damage, package remained intact for well over goal of 5 uses

4. Impact testing – Design Implications • Package absorbs a substantial amount of energy • Saddle support thickened to increase strength at failure point • Small saddle area makes loading somewhat difficult • Saddle thickened to ensure adequate area for core • Core length measured – out of spec, addressed with core manufactureres • Horseshoes with connection at base created a gap after impacts • Horseshoes will be free-floating going forward so they can return to their original positions

5. Spec document • See needs and specs status check document

6. Vibration test results • 3 hours, double stacked container, movement in vertical direction only • Top roll collapse at 24 minutes • Likely due to core plug failure due to compressive stress, followed by failure of core • Opposite side of core showed signs of similar damage but not total failure • Wear seen around circumference of core suggests roll rotated during test • Package condition • No failure of components • No cracking • Straps intact • Noticeable wear due to collapsed roll vibrating against components

7. Vibration test results Core Plug

8. Vibration test - Design implications • Core movement in y-direction may be contributing factor to failure • Solution: reduce/eliminate horseshoe clearance on core to restrict movement • Core and core plug failure • Solution: more robust core plug • Solution: larger saddle contact area (would affect max roll width)

9. New package – 3d • Overall height reduced by 4” • Horseshoe now secures the roll from above

10. Cost/benefit • Current unit cost $250 – goal of $120 • In order to drive unit price down, package reuse must be emphasized • Lean toward higher volume customers to make return feasible • Package design should be bid out to multiple vendors for potential cost savings • Increased throughput, reduced CT • Reduction of DVB due to repack

11. Going forward • Latest design - vibration and impact testing • Larger rolls • Package design must be scaled to fit • Consider cost benefit analysis • Review SOP, train operators • Seek customer approval for new package