Developing Sustainable Packaging using NX John Manderfield Director of Creative Design Consolidated Container Company [email_address]

Agenda Welcome Intro to Consolidated Container Role of Shipping Containers Use of Package Optimization Program (POP) to optimize shipping container Case Study: Trigger Sprayer Customer wants new trigger bottle Designed it: does not fit in box Went to POP - developed range of sizes Went back to NX to resize numerous parts to pack out efficiently

Welcome

Intro to Consolidated Container

Role of Shipping Containers

Use of Package Optimization Program (POP) to optimize shipping container

Case Study: Trigger Sprayer

Customer wants new trigger bottle

Designed it: does not fit in box

Went to POP - developed range of sizes

Went back to NX to resize numerous parts to pack out efficiently

Agenda NX Tools Used Sketches, Parameters, Expressions Measure Bodies: Associative: remembers volume check Sticky Call-out: shows on screen True Shading NX Tools We Want To Get To Goal Seek: drive height to reach target internal volume UDF: would this help? Reuse Library: common sprayer to all shapes NX Modules To Consider Assemblies Knowledge Fusion: extra cost? Tips & Tricks from Audience? Questions & Answer Session

NX Tools Used

Sketches, Parameters, Expressions

Measure Bodies:

Associative: remembers volume check

Sticky Call-out: shows on screen

True Shading

NX Tools We Want To Get To

Goal Seek: drive height to reach target internal volume

UDF: would this help?

Reuse Library: common sprayer to all shapes

NX Modules To Consider

Assemblies

Knowledge Fusion: extra cost?

Tips & Tricks from Audience?

Questions & Answer Session

What is “Sustainable” Packaging? Packaging over its life cycle that: Meets society’s needs for performance and quality of life (social) Minimizes life cycle environmental impacts (environmental) Is efficient in how it uses resources (environmental) Is cost effective (economic) Is safe, meets all regulatory requirements and is easy to use (environmental and social) Does not compromise the ability of future generations to meet their needs (economic, environmental and social) Source: Dow Chemical

Packaging over its life cycle that:

Meets society’s needs for performance and quality of life (social)

Minimizes life cycle environmental impacts (environmental)

Is efficient in how it uses resources (environmental)

Is cost effective (economic)

Is safe, meets all regulatory requirements and is easy to use (environmental and social)

Does not compromise the ability of future generations to meet their needs (economic, environmental and social)

Source: Dow Chemical

How Does Consolidated Container Contribute? Rigid Packaging Extrusion Blow Molding

Rigid Packaging

Extrusion Blow Molding

My Role Director of Creative Design Industrial Design Subject Matter Expert PLM World User Group (past chair) Drive Innovation Recognize Trends… … drive efficient packaging using POP

Director of Creative Design

Industrial Design

Subject Matter Expert

PLM World User Group (past chair)

Drive Innovation

Recognize Trends…

… drive efficient packaging using POP

Thinking…Inside the Box

Recognizing a Need for Efficiency CCC makes Bottles Shipped to Filler (empty) Filled, Capped, Labeled Boxed in shipping cartons Stacked on pallets Placed inside trailers/containers Shipped to store/DC Placed on store shelf

CCC makes Bottles

Shipped to Filler (empty)

Filled, Capped, Labeled

Boxed in shipping cartons

Stacked on pallets

Placed inside trailers/containers

Shipped to store/DC

Placed on store shelf

Packaging Optimization Program (POP) Approach TOPS from Tops Engineering Analyzes dimensions of shapes – space fits into other shapes Optimizes for shipping purposes

TOPS from Tops Engineering

Analyzes dimensions of shapes – space fits into other shapes

Optimizes for shipping purposes

New 22oz Trigger Design Optimized with POP Digital Rendering Submitted to Customer Marketing is OK with it Consumer Focus Group loves it Operations hates it no one asked him Incorrect capacity Does not fit in box Wants a 32oz size as well

Digital Rendering Submitted to Customer

Marketing is OK with it

Consumer Focus Group loves it

Operations hates it

no one asked him

Incorrect capacity

Does not fit in box

Wants a 32oz size as well

Using POP to optimize the design

POP Inputs: Bottle & ShipCase Analyze with POP

Analyze with POP

POP Inputs: Pallet

POP Solution: Graphics

POP Solution: Data

POP Solution So…what is all this telling me? I just want to get the bottles into the box! The Bottle “fits”… but could fit better

So…what is all this telling me?

I just want to get the bottles into the box!

The Bottle “fits”… but could fit better

Sustainable Design Goal Setting VERSATILE CASE: make two sizes fit same box VOLUME GOAL: 22oz AND 32oz CASE GOAL: Increase Cases 19.84 (too small) Volume (oz) 105 Cases 0% 22oz &32 Trigger Start Part EFFICIENCY GAIN FLEX? TO FROM

VERSATILE CASE: make two sizes fit same box

VOLUME GOAL: 22oz AND 32oz

CASE GOAL: Increase Cases

Bottle Start Part

Progression Bottle Optimization

Sustainable Design Goal Setting VERSATILE CASE: make two sizes fit VOLUME GOAL: 22oz AND 32oz CASE GOAL: Increase Cases 22 & 32 22 & 32 22 (32 won’t fit) 22 & 32 19.84 (too small) Volume (oz) 14% 120 n/a 2.35” 2.44” Depth 125 125 125 105 Cases 20% TARGET > 1.0” MAX Current Height 20% TARGET 3.65” 3.2” Width 20% NO 2.15” 2.44” Depth 0% 22oz Trigger Start Part EFFICIENCY GAIN FLEX? TO FROM

VERSATILE CASE: make two sizes fit

VOLUME GOAL: 22oz AND 32oz

CASE GOAL: Increase Cases

Sustainable Design Goal Setting Increase Width 3.2 to 3.65” Makes bottle larger Increase Height up to 1” Makes bottle larger Decrease Depth 2.44 to 2.15” Makes bottle smaller

POP Approach - Limitations POP does not understand complex geometry of the part inside the carton Example: round bottles do not maximize cube of box NX can’t read POP data directly (manual reentry) POP can’t read NX data

POP does not understand complex geometry of the part inside the carton

Example: round bottles do not maximize cube of box

NX can’t read POP data directly (manual reentry)

POP can’t read NX data

Wrap Up NX Tools Used Sketches, Parameters, Expressions Measure Bodies: Associative: remembers volume check Sticky Call-out: shows on screen True Shading NX Tools We Want To Get To Goal Seek: drive height to reach target internal volume UDF: would this help? Reuse Library: common sprayer to all shapes NX Modules To Consider Assemblies Knowledge Fusion: extra cost? Tips & Tricks from Audience? Questions & Answer Session

NX Tools Used

Sketches, Parameters, Expressions

Measure Bodies:

Associative: remembers volume check

Sticky Call-out: shows on screen

True Shading

NX Tools We Want To Get To

Goal Seek: drive height to reach target internal volume

UDF: would this help?

Reuse Library: common sprayer to all shapes

NX Modules To Consider

Assemblies

Knowledge Fusion: extra cost?

Tips & Tricks from Audience?

Questions & Answer Session

Exploration of Bottle Designs Rendered with Basic Shading

Exploration of Bottle Designs Rendered with Basic Shading

Exploration of Bottle Designs Rendered with NX True Shading <1 min & real time w/Shape Studio

Developing Sustainable Packaging using NX Thanks to: John Krzysik, Design Engineer, Consolidated Container For his support of this presentation