Notes

Five Amazing Solutions To Optimize Logistics
There are a variety of innovative solutions to optimize packaging and logistics management. After all, the greater the amount of component parts transported in one fleet from one location to another can save significant costs for any company.

Designing and manufacturing interior packaging dunnage for large bulk bin containers, small hand held container totes and custom steel racks will effectively increase product safety, improve warehouse floor space and decrease logistics costs.

The fundamentals to a successful design and build consists of excellent communication between customer and supplier along with meeting all deadlines within an agreed timeframe.

When a customer sends an RFQ (request for quote) to the supplier for a certain packaging build, the supplier then sends a quote with all costs included along with a lead time (the time duration for completion). However, all projects are not treated equal as it can take a lot more time and effort to complete an advanced complex design as opposed to a simpler package.

Efficient route planning is also essential for optimizing logistics management, but we will only cover the packaging solutions in this article.

1. COLLAPSIBLE RACK


- Collapsible racks serve the same purpose as any other standard racks, but these particular racks have the ability to fold down when the parts are unloaded.
- The advantage of the folding capability is that it increases the stacking quantity amount in the freight trailer.
- These are a great option when returning racks because the collapsible feature enables increased storing efficiency during transportation.
- Steel collapsible racks are durable and robust and can carry a heavy load.
- The overall footprint and height can be customized to fit any requirements.
- The foam dunnage utilized in this example below is the holding mechanism for the component part and they’re removable, consequently allowing the folding feature to be successfully executed without interference.

2. TWO SIDED BAG FRAME MOUNTED ON DOLLY

- A standard bag rack typically has bag inserts that can only be loaded and unloaded from one side. The advantage for this 2 sided bag frame is the ability to load and unload on 2 sides as opposed to 1. Consequently, this dramatically increases part density and optimizes logistics.
- The main function that enables the 2 sided loading feature is the swivel bearing that the steel frame is mounted on. As a result, it allows the frame to rotate 360 degrees and helps the operator to load all parts on both sides (operator will need to rotate the frame 180 degrees to access the opposite side).
- A locking mechanism is installed on each opposite corner to ensure the steel frame will come to a stop once rotating the frame 180 degrees.
- Bag carts enable easy mobility for operators without the need of a forklift within a manufacturing plant due to the caster wheels.
- The Fabric bags are typically made from 18 oz. vinyl material reinforced with webbing for extra strength, which results in a reliable and firm solution for the component part holding mechanism. Ultimately, they contain pockets (referred to as cells) where the component parts will rest in.

3. BULK BIN INTERIOR DUNNAGE

- While there are numerous combinations for building interior bulk bin container dunnage, the most common methods typically consists of utilizing plastic corrugated sheets and cross linked foams.
- As shown in the top load bulk container example below, the cross linked foam rails are waterjet cut to the exact size and shape and fastened to the plastic corrugated base (known as base pads).
- 4 LB. cross linked foam rails is the typical choice for most projects, but 6 LB. or 8 LB. cross linked foam rails are necessary if extra strength is required.
- In this particular case, the base pads are bent to a “V” shape with a hot wire bender to allow the foam rails to be assembled on an angle to accommodate for the “wheel flare” component.
- The bend in the base pads enable 3 layers of assemblies to be placed in the bin, ultimately allowing a higher density for optimal logistics results.
- Bulk containers usually come in many different options and footprint sizes to accommodate all your needs.

4. CANTILEVER RACK

- Cantilever racks are essentially a steel frame with extended tubes in the center for the parts to rest on.
- This is a cost effective solution as it requires less steel structure in comparison to other complex custom steel racks.
- The component parts can be stacked together during the loading process, consequently allowing a higher density and optimizing logistics management.
- The stacking caps on top of each corners enable the stacking feature and the bottom fork tubes enable easy material flow movement.

5. BAG RACK WITH DIFFERENT SIZE POCKETS

- Bag racks can accommodate for all types of part shapes and sizes.
- The advantage these style of racks have is the capability to hold multiple variant component parts with ease.
- If a program requires multiple parts to be loaded and unloaded simultaneously at a work station, then this method can provide an exceptional solution.
- As shown in the images below, the large cell is holding the large red component and the small cell is holding the small green component. In essence, this 2 cell method salvages the need for 2 separate packaging builds as it carries both parts, even though the shapes and sizes are noticeably different.
- The customer can save time and money with avoiding multiple design and build programs with this optimal solution.

Website: https://plexformps.com/