CHAPTER 5: PROTECTIVE PACKAGING AND MATERIALS HANDLING
CHAPTER 5: PROTECTIVE PACKAGING AND MATERIALS HANDLING
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講義:小保羅·R·墨菲《MBA物流學》(5)
PART II
ANSWERS TO END-OF-CHAPTER QUESTIONS
CHAPTER 5: PROTECTIVE PACKAGING AND MATERIALS HANDLING
1. How do product characteristics influence packaging and materials handling considerations?
One consideration is a product’s physical characteristics; substances exist in three forms—solid, liquid, gas—and each form has specific packaging requirements. For instance, metal cylinders are one method for the packaging of gases, while metal pails can be used for the packaging of liquids. Another physical characteristic is the product’s ability to withstand the elements; coal can be exposed to rain, whereas salt piles cannot. In a similar vein, some products can be exposed to freezing conditions, while others cannot. Product density (weight per volume) is yet another physical characteristic that can affect packaging conditions.
2. Discuss some of the packaging requirements associated with hazardous cargo.
The specific requirements differ for each hazardous commodity, but all of them involve labeling, packaging and repackaging, placing warnings on shipping documents, and notifying carriers in advance. A common requirement for transferring flammable materials is that the vehicle and the receiving or discharging device both be electrically grounded. Packages, containers, trailers, and other vehicles carrying hazardous materials must carry distinct signs, or placards, identifying the hazard.
3. What is the building-blocks concept? How is it applied to the handling of packaged goods?
The building-block concept is a key factor in unit loads. Building blocks have certain dimensions that allow them to stack or load on a pallet or similar piece of equipment. The building-blocks hierarchy is important to remember because each of the different building blocks is inside another and their total effect must be to protect the product. They function in a complementary sense.
4. The chapter describes approximately 10 functions that a protective package should accomplish. Does every package have to accomplish every function? Explain.
Packages are designed to perform a number of protective functions: protect the product from physical damage; be strong enough to support additional boxes as part of the building-block concept; provide uniform weight distribution within the package; and allow enough exterior space for shipping and identification labels to be attached.
A thoughtful examination of the 10 functions would suggest that not every function is applicable to every package. For example, tampering tends to be more important with food and drugs than with, say, paper products. In addition, separation of the contents to prevent undesired contact is likely more important with fragile items such as glassware.
5. Discuss the relationship between the level of protective packaging used relative to the packaging requirement of common carriers.
Carriers’ tariffs and classifications influence, if not control, the type of packaging and packing methods that must be used. In freight classification documents, the type of packaging is specified. The carriers established these different classifications for two main reasons. First, packaging specifications determined by product density encourage shippers to tender loads in densities that make best use of the equipment’s weight and volume capabilities. Second, specifications that deal with protective packaging reduce the likelihood of damage to products while they are being carried.
6. Discuss the role of labeling in logistics management.
Once the material being packaged is placed into the appropriate container and sealed shut, it becomes necessary to label the container. Whether words or code numbers are used depends on the nature of the product and its vulnerability to pilferage. Retroflective labels that can be read by optical scanners may also be applied. Batch numbers are frequently assigned to food and drug products, so that they may be more easily traced in case of a product recall. Many regulations govern the labeling of packages, including the labeling of weight, specific contents, and instructions for use. Labeling can also be used to enable a container to pass through Customs and other inspections as it travels in international commerce.
7. Why is it important to recognize that labeling requirements may differ from country to country?
Failure to comply with labeling requirements could subject the offending organization to surcharges, administrative fees, and/or penalty charges. As a general rule, labeling requirements and enforcement tend to be more stringent in economically developed countries than in economically developing countries.
8. Describe some of the devices that are used to monitor conditions during the journey that a shipment makes.
Various packaging material manufacturers and trade organizations provide free package testing that attempts to duplicate shipping hazards such as vibration, dropping, compression, and rough handling, among others. Actual monitoring of the environment the package must pass through can be done by enclosing recording devices within cartons of the products that are shipped. More sophisticated devices record over time a series of variables, such as temperature, humidity, and acceleration force and duration.
9. What are some environmental disadvantages to plastic packaging?
One of plastic’s most frequently cited shortcomings is the length of time that it takes to biodegrade, which can be up to several hundred years. Moreover, the production of plastic products is dependent on petroleum, which is a diminishing natural resource (and an extremely costly resource in recent years). A third environmental concern with plastic packaging is that sometimes plastic litter unintentionally ends up killing large numbers of marine animals.
10. What environmentally friendly packaging strategies might a firm adopt?
One is to reduce the amount of packing materials used, such as the use of just one material. A second packaging strategy is to use environmentally friendly packaging materials, such as postconsumer recycled content. A third strategy is to use reusable containers, such as refillable glass beverage bottles. A fourth environmentally friendly strategy is to retain or support services that collect used packaging and recycle it.
11. What information is needed to design a protective package properly?
Three important kinds of information are required: the severity of the distribution environment; the fragility of the product to be protected; and the performance characteristics of various cushion materials.
12. What are some potential advantages to the unit load?
One advantage is additional protection to the cargo because the cartons are secured to the pallet by straps, shrink-wrapping, or some other bonding device. A second advantage is that pilferage is discouraged because it is difficult to remove a single package or its contents. The major advantage of the unit load is that it enables mechanical devices to be substituted for manual labor.
13. Discuss the disadvantages of the unit load.
One disadvantage is that it represents a larger quantity of an item than a single box and may be of limited value to organizations that deal in small quantities. In addition, the mechanical devices, such as a forklift, that can be substituted for manual labor can be very expensive. Yet another drawback is a lack of standardization of pallet sizes, especially in the
14. What trade-offs exist between wood, plastic, and steel pallets?
Wood pallets are relatively inexpensive compared with plastic and steel pallets. However, plastic and steel pallets have much greater longevity relative to wood. Steel pallets can last for over 20 years—a wood pallet might last for one use! Unlike plastic and steel, wood pallets can break and splinter and thus pose safety dangers to workers as well as perhaps necessitating repair costs. Another disadvantage to wood pallets is that they are much heavier than plastic and steel. Wood and plastic pallets are much more flammable than steel.
15. Is the slip sheet currently a viable alternative to the pallet? Why or why not?
A slip sheet, or flat sheet of either fiberboard material or plastic, is placed under the unit load and takes up less space than a pallet. The text suggests that advances in technology have created stronger plastics for slip sheets, which has led to a dramatic decrease in product damage. Improved damage rates and low cost ($.90 to $1.50 per slip sheet) suggest that slip sheets could account for 30% of product shipments by 2010.
16. What issues does the logistics manager face once unit loads have been placed onto a transportation vehicle?
One consideration is how to load pallets, cartons, and the like into a transportation vehicle— some cartons cannot be laid on their sides or cannot have other cartons placed on top of them. Bracing or inflatable dunnage bags are used to fill narrow empty spaces, but even when properly braced, various forces such as vibration, pitch, and roll can still cause damage. Some goods are so heavy that they utilize a vehicle’s weight capacity without filling its cubic capacity; these loads must be carefully braced and the weight must be distributed as evenly as possible.
17. Discuss the various handling characteristics associated with bulk cargoes.
Bulk materials are loose rather than in packaged form and are handled by pumps, shovel devices, conveyor belts, or the mere force of gravity. One handling characteristic for bulk materials is density, and this can affect the amount of product that can be loaded onto a transport vehicle. A material’s angle of repose is the size of angle that would be formed by the side of a conical stack of that material; the greater the angle, the higher the pile of material that can be placed on a specific land area. Bulk liquids have unique handling characteristics and their resistance to flow is measured as viscosity, which can be lowered by increasing the temperature of a liquid. Gases have unique handling properties, although most of them are handled within completely enclosed pipeline systems.
18. Describe two material handling principles. Which of the two do you believe is more important? Why?
The text lists 10 materials handling principles developed by The College-Industry Council on Material Handling Education. Any two of these principles can be described, and the student can justify which one she / he believes to be more important.
19. Why is it important that materials handling be aligned with an organization’s objectives, customers and products?
The text indicates that this should be common sense but relates an anecdote about a consumer products company that redesigned one of its storage facilities with the primary purpose to be state of the art in terms of materials handling equipment. Less than a year later, the storage facility had to be redesigned because the state of the art materials handling equipment was inconsistent with the type of products sold by the company as well as with its customers’ ordering requirements.
20. Does your hometown have mandatory recycling requirements? If so, what kinds of products must be recycled?
The answers to this question can provide a stimulating discussion assuming that the students come from different geographic areas (even with the same metropolitan area). It can be interesting to learn that side-by-side towns have vastly different recycling requirements as well as to explore the logistical implications of the various recycling requirements.
PART III
EXAMINATION QUESTIONS
CHAPTER 5: PROTECTIVE PACKAGING AND MATERIALS HANDLING
Multiple Choice Questions
1. Which of the following statements is false?
a. some products can be exposed to freezing weather; others cannot
b. perishable products require special packaging as they move from source to customer
c. a product’s chemical characteristics have little or no influence on the way they are handled
d. the various properties of goods must be made known to consumers to help them make the correct buying decision and properly care for the product
e. all are true
(c; pp. 107-108)
2. Which of the following statements regarding perishable products is false?
a. they require special packaging
b. they require special monitoring
c. they require special loading
d. they require special storage
e. all are true
(e; p. 108)
3. Legislation passed after the ____ requires petroleum carriers and tank farms to have in place extensive response plans for dealing with possible spills.
a. Exxon Valdez Oil Spill
b. terrorist attacks of September 11, 2001
c. Persian Gulf War of 1991
d. Vietnam War
(a; p. 109)
4. What is a placard?
a. a device used to monitor engine speed
b. a distinct sign that identifies hazardous material
c. protective wrap for shipments that might freeze while in transit
d. a type of manually operated materials handling equipment
(b; p. 109)
5. The building blocks concept is associated with which logistics function?
a. warehousing
b. packaging
c. materials handling
d. inventory management
(b; p. 109)
6. ____ refers to materials used for the containment, protection, handling, delivery, and presentation of goods.
a. Packaging
b. A box
c. Materials handling
d. Procurement
(a; p. 110)
7. Which of the following is not a general function of packaging?
a. to promote
b. to protect
c. to facilitate product handling
d. to identify (label)
e. all are general functions
(c; p. 110)
8. All of the following are protective functions of packaging except:
a. enclosing the materials
b. being tamper-proof
c. providing uniform weight distribution
d. cushioning the contents
e. all are protective functions
(e; pp. 110-111)
9. A “box-maker’s certificate”:
a. refers to what box makers receive upon finishing their training
b. is given in recognition of superior box making ability
c. assures that boxes are free from any visible defects
d. assures rails and truckers that boxes are sufficiently sturdy to meet their handling requirements
(d; p. 113)
10. ____ regulates the packaging of international air shipments.
a. An individual airline
b. The United Nations
c. A country’s federal government
d. The International Air Transport Association
(d; p. 114)
11. Which of the following is false?
a. package labeling is usually done at the end of the assembly line
b. code numbers are preferable to words for labeling a product
c. some firms are moving from one dimensional to two dimensional bar codes
d. batch numbers are frequently assigned to food and drug products
(b; p. 114)
12. As a general rule, labeling requirements and enforcement tend to be more stringent in ____ countries than in ____ countries.
a. larger; smaller
b. economically developing; economically developed
c. economically developed; economically developing
d. smaller; larger
(c; p. 114)
13. Which of the following is not a type of information that is needed to develop a protective packaging system?
a. severity of the distribution environment
b. the budget for packaging
c. fragility of the product to be protected
d. performance characteristics of various cushioning materials
e. all are types of information
(b; p. 117)
14. Each of the following is a shipping hazard that a package may be exposed to except:
a. retraction
b. vibration
c. compression
d. extreme temperature
e. all are shipping hazards for a package
(a; p. 117)
15. The ____ ordinance concerning recycling is indicative of the direction in which the world is moving.
a.
b. French
c. British
d. German
(d; p. 119)
16. Which of the following is not a characteristic of plastic packaging?
a. lack of versatility
b. takes a long time to biodegrade
c. plastic is dependent on petroleum
d. plastic litter can kill marine animals
e. all are characteristics of plastic packaging
(a; p. 119)
17. The text suggests that firms can adopt ____ environmentally-friendly packaging strategies.
a. two
b. three
c. four
d. five
(c; p. 119)
18. Which of the following is not an environmentally-friendly packaging strategy that firms might adopt?
a. reduce the amount of packing materials used
b. use more environmentally-friendly packaging materials
c. use reusable containers
d. retain or support services that collect the used package and recycle it
e. all are strategies
(e; pp. 119-120)
19. ____ systems consider the reverse flow of products, their reuse, and the marketing and distribution of recovered products.
a. Eco-
b. Open-loop
c. Retro-movement
d. Closed-loop
(d; p. 120)
20.
a.
b.
c. The
d.
(c; p. 120)
21. The basic unit in unit loading is:
a. a box
b. a crate
c. a pallet
d. a container
(c; p. 121)
22. A unit load involves:
a. a convoy of rail cars carrying the same product
b. loading an entire vehicle with shipments of three boxes or less
c. the usage of a pallet rack system of storage
d. securing one or more boxes to a pallet or skid in order to handle by mechanical means
(d; p. 121)
23. The major advantage of the unit load is:
a. its environmental friendliness
b. mechanical devices can be substituted for manual labor
c. its value to companies that deal in small quantities
d. that it simplifies transportation
e. none of the above
(b; p. 122)
24. Which of the following is false?
a. the unit load is of limited value to shippers who deal in smaller quantities
b. unit loads may discourage pilferage
c. the unit load allows mechanical devices to be substituted for manual labor
d. pallets suffer from a lack of standardized sizes
e. all are true
(e; p. 122)
25. A major drawback to steel and plastic pallets is their ____.
a. weight
b. incompatibility with existing forklifts
c. price
d. lifespan
(c; p. 122)
26. ____ pounds is a significant weight in many logistics systems because it represents the approximate weight at which there is a noticeable increase in injuries.
a. 40
b. 50
c. 60
d. 75
(b; p. 124)
27. Because of the height that a pallet takes up in a vehicle or warehouse, a method of achieving the advantages of a pallet without losing space is:
a. slip sheets
b. optimum cost reliability point
c. mini-skid system
d. low profile pallet system
(a; p. 124)
28. Inflatable ____________ fill void space and function as both a cushion and a brace.
a. tubes
b. rafts
c. mattresses
d. dunnage bags
(d; p. 124)
29. The short distance movement of material between two or more points refers to:
a. warehousing
b. transportation
c. materials handling
d. materials management
(c; p. 126)
30. A ____ is a uniform, sealed reusable metal box in which goods are shipped.
a. container
b. vessel
c. trailer
d. crate
(a; p. 126)
31. A dry bulk material’s ____ is important for determining the quantity that can be stored in a given location.
a. market value
b. angle of repose
c. specific gravity
d. viscosity
(b; p. 128)
32. The greater a bulk material’s angle of repose, the ____.
a. higher the pile of materials that can be placed on a specific land area
b. greater its resistance to flow
c. higher its specific gravity
d. harder it is to move
(a; p. 128)
33. Each of the following is a question associated with materials handling, except:
a. how will the product be handled?
b. what kind of equipment is needed to handle or store the product?
c. in what form will the product be?
d. how much is the product worth?
e. all of the above are questions
(d; p. 128)
34. The ____ principle of materials handling reminds us that the shortest distance between two points is a straight line.
a. ergonomic
b. system
c. standardization
d. work
(d; p. 129)
35. Which of the following is false?
a. in a part-to-picker system, the pick location is brought to the picker
b. forklifts can be dangerous
c. automation refers to equipment that complements, rather than replaces, human contact
d. racks and bins are examples of storage equipment
e. all are true
(c; p. 130)
True-False Questions
1. The physical characteristics of some goods change while they are moving in the logistics channel. (True; p. 107)
2. Certain products should not, for health or safety reasons, be packaged together. (True; pp. 108)
3. Compressed gases are one category of hazardous materials. (True; p. 109)
4. Legislation passed during the 1970s requires petroleum carriers and tank farms to have in place extensive response plans for dealing with spills. (False; p. 109)
5. Placards are distinct signs that identify hazardous materials. (True; p. 109)
6. Procurement can be thought of in terms of the building-blocks concept. (False; p. 109)
7. One general function of packaging is to facilitate a product’s handling. (False; p. 110)
8. The promotional and protective functions of packaging sometimes conflict. (True; p. 110)
9. Protective packaging should be able to perform multiple functions. (True; pp. 110-111)
10. A “box maker’s certificate” assures that boxes are free from any visible defects. (False; p. 113)
11. Regardless of whether the shipper or carrier is responsible for damage in transit, the shipper specifies the level of packaging protection to be used. (False; pp. 113-114)
12. The packaging requirements for airlines and express delivery companies tend to be less detailed than those used by rail and motor carriers. (True; p. 114)
13. Most package labeling takes place at the end of the assembly line. (True; p. 114)
14. As a general rule, labeling requirements and enforcement tend to be more stringent in larger countries (based on population) than in smaller countries. (False; p. 114)
15. When new products or new packaging techniques are about to be introduced, it is somewhat advisable to have the packages pre-tested. (True; p. 117)
16. Under the German recycling ordinance, the final consumer has the ultimate responsibility for packaging disposal. (False; p. 119)
17. Plastic packaging tends to be cheaper, more versatile, and more consumer-friendly than paper packaging. (True; p. 119)
18. Polyvinyl chloride (PVC), commonly referred to as vinyl, is considered a friendly plastic because it has few, if any, potential side effects. (False; p. 120)
19. Reusable containers work best in a closed-loop system. (True; p. 120)
20. The
21.
22. The basic unit in unit loading is the retail package. (False; p. 121)
23. When a unit load is secured to a pallet, it is more difficult for pilferage to take place. (True; p. 122)
24. The major advantage of the unit load is that it enables mechanical devices to be substituted for manual labor. (True; p. 122)
25. There are no disadvantages to the unit load. (False; p. 122)
26. Lift trucks are the common workhorse used around warehouses to move pallets. (True; p. 122)
27. Plastic pallets tend to be less expensive than wooden or steel pallets. (False; p. 122)
28. Steel pallets have longer lifespans than wooden or plastic pallets. (True; p. 124)
29. Advances in technology have created stronger plastics that can be used for slip sheets and this has resulted in a corresponding decrease in damage rates. (True; p. 124)
30. For surface cargo, the next-sized building block beyond the unit load is the pallet load. (False; p. 124)
31. Load-planning software can be used to suggest how to load a container with different sizes of cartons. (True; p. 124)
32. A “weighed out” container refers to one that has been weighed prior to its departure from a container yard. (False; p. 125)
33. Materials handling deals with the short distance movement of the material between two or more points. (True; p. 126)
34. Ocean carriers and railroads have both developed methods of handling two or more containers at one time. (True; p. 126)
35. A material’s angle of repose refers to the size of angle that would be formed by the side of a conical stack of that material. (True; p. 128)
36. Viscosity refers to a bulk material’s water content. (False; p. 128)
37. Ergonomics refers to the science that seeks to adapt work or working conditions to suit the abilities of the worker. (True; p. 129)
38. The planning principle of materials handling suggests that the material handling plan should be in line with the strategic objectives of the organization. (True; p. 129)
39. Automatic guided vehicles (AGVs) are an example of mechanized materials handling equipment. (False; p. 130)
40. As a general rule, picker-to-part systems are preferable to part-to-picker systems. (False; p. 130)
PART IV
CASE SOLUTIONS
CASE 5-1 LET THERE BE LIGHT LAMP SHADE COMPANY
Question 1: How many style A shades can be loaded into an intermodal container?
The intermodal container holds 2,720 cubic feet, however, the top six inches is of no use. It will hold 2,560 style A shades.
Question 2: How many style B shades can be loaded into an intermodal container?
Style B shades could be stacked two packages high with the square foot on the bottom. Each column would hold 12 shades. There would be 8 x 40, or 320 columns of 12, yielding 3,840 lamp shades, and would weigh less than 40,000 pounds.
Question 3: How many style C shades can be loaded into an intermodal container?
Style C shades could be stacked the same way as style B and a container would hold 320 columns of 20, yielding 6,400 lamp shades. However, this would exceed the 44,000 pound weight limit. Each shade weighs 10.1 pounds; dividing that into 44,000 pounds yields approximately 4,350 lamp shades.
Question 4: What are the total costs of delivering the style A shades to the port of importation?
Item
Cost parameters
Total cost
Shade
$4 x 5,400
$21,600
Packaging
$.60 x 5,400
$3,240
Intermodal containers (3)
Container drayage to
Port of Oakland
$1,000 x 3
$3,000
Insurance
$27,800 x .02
$556
Ocean freight rates (a)
$22 per 2,000 pounds
$594
Ocean freight rates (b)
$22 per 40 cubic feet
$2,970
Pick higher of (a) or (b)
$2,970
Total
$31,366
Question 5: What are the total costs of delivering the style B shades to the port of importation?
Item
Cost parameters
Total cost
Shade
$5 x 5,400
$27,000
Packaging
$2 x 900
$1,800
Intermodal containers (2)
Container drayage to
Port of Oakland
$1,000 x 2
$2,000
Insurance
$30,800 x .02
$616
Ocean freight rates (a)
$22 per 2,000 pounds
$614
Ocean freight rates (b)
$22 per 40 cubic feet
$1,960
Pick higher of (a) or (b)
$1,960
Total
$33,376
Question 6: What are the total costs of delivering the style C shades to the port of importation?
Item
Cost parameters
Total cost
Shade
$6 x 5,400
$32,400
Packaging
$3 x 540
$1,620
Intermodal containers (2)
Container drayage to
Port of Oakland
$1,000 x 2
$2,000
Insurance
$36,020 x .02
$720
Ocean freight rates (a)
$22 per 2,000 pounds
$600
Ocean freight rates (b)
$22 per 40 cubic feet
$1,238
Pick higher of (a) or (b)
$1,238
Total
$37,978
Question 7: Which style would you recommend? Why?
From the relevant data, style A is least expensive.
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