Thomas Benner Brandon Kilbury Phillip C. McKee Justin Mintz Jason Ryan RIT MSD II FINAL REVIEW ESTAR WIDE FORMAT SHIPPING CONTAINER

 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 MSD I RECAP

 Impact Tests performed at Kodak  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 IMPACT TESTING - RESULTS

 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 IMPACT TESTING – DESIGN IMPLICATIONS

SPEC DOCUMENT  See needs and specs status check document

 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 VIBRATION TEST RESULTS

Core Plug

 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) VIBRATION TEST - DESIGN IMPLICATIONS

NEW PACKAGE – 3D  Overall height reduced by 4”  Horseshoe now secures the roll from above

 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 COST/BENEFIT

 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 GOING FORWARD