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1. Tutorial files

Project file: Matches.stb

Report file: Matches.doc

2. The problem

You are required to design a package chain (case/pallet/truck) to enable transporting the maximum number of kitchen match boxes per truck.

Match box

240 kitchen matches box

Length (mm)

Width (mm)


Weight (kg)







Case constraints

Number of boxes per case


Maximum dimensions

Length (mm)

Width (mm)

Height (mm)





Cardboard thickness (mm)


Number of thicknesses

in length direction

in width direction

in height direction





Estimated case weight (kg)



Maximum pallet height (mm)




Pallet EUR2

Length (mm)

Width (mm)

Height (mm)

Weight (kg)








Truck trailer



Length (mm)

Width (mm)

Height (mm)







3. Solving with StackBuilder


Launch StackBuilder

Use either desktop or menu shortcut clip_image007 to launch PLMPack StackBuilder.


Create a new project


Use either menu File>New or toolbar "New" clip_image011 to create a new project.

Once you have entered a project name and a description in the "Create new document..." form, the OK button should be enabled and you can click it.



The document explorer now shows your project.



Create a new box


Use either menu "Tools>New Box" or toolbar "New Box" button clip_image017 or right click the "Boxes" branch in document explorer tree and select "Add new box" on context menu to create a new box.

Fill the "Create new box" form with the correct name, description, dimensions and weight before clicking OK.




You can check that the box "Match box" now appears under the Boxes branch in the document explorer tree.


Create a new pallet


Use either menu "Tools>New Pallet" or toolbar "New pallet" button clip_image021or right click the "Pallets" branch in document explorer tree and select "Add new pallet" on context menu to create a new pallet.

Fill the "Create new pallet" form with the correct name, description, dimensions and weight before clicking OK.


You can check that the pallet "EUR2" now appears under the Pallet branch in the document explorer tree.

Notice that the "Case optimization" tool clip_image025is now enabled. This indicates that you could actually proceed with case optimization from now on. However, we choose to create the truck before although

Create a new truck


Use either menu "Tools>New Truck" or toolbar button "New truck" clip_image027 or right click the "Trucks" branch in document explorer tree and select "Add new truck" on context menu to create a new truck.

Fill the "Create new truck" form with the correct name, description, dimensions and weight before clicking OK.



Find optimal case


Use either menu "Tools>Search for optimal case" or toolbar button "Search for optimal case" clip_image025[1]to show case optimization form.

Box and pallet appears to be already set because only one box and only one pallet are already defined.

Set the number of boxes per case to 150.

Set all maximum case dimensions to 600 mm.

Set all minimum case dimensions to 50 mm.

Set wall thickness to 4 mm.

Define 2 walls in the direction of length and width but 4 in the direction of height.

Press optimize. The software then test all the possible arrangement of boxes and retain the best pallet layouts for each arrangement. All the solution are then ordered by number of cases per pallet.

You can click on any row of the grid to visualize the case arrangement on the left picture and the corresponding pallet layout on the right.

Among 548 solutions, 72 solutions gives the maximum number of case per pallet which appears to be 56.

Change all three maximum case dimensions to 400 mm and press Optimize again.

The number of tested solutions shrinks to 44 and there are now only 4 solutions which lead to 56 cases per pallet.



Select a solution


Evaluate all the best solutions by navigating the grid either by clicking a row or by using arrow keys.

Click the "Create case and pallet analysis" button to insert the case of boxes and matching pallet analysis solution in your project.

You could reproduce this last step for all the solutions you want to investigate.

Click the "Close" button when you are finished


You can check that a new case of boxes was created under the "Cases" branch and a new analysis under the "Analyses" branch in the document explorer tree.

Also, the newly created analysis is visible in a view that automatically opened. This analysis only contains the selected solution.

Add truck analysis

The selected solution appears as a light bug under the created analysis branch.

Right click it and in the context menu click "Add new truck analysis"


As only one truck was defined in the project, it is already selected.

Use all the default parameters as all pallet position are allowed and no margin is required.

Click OK to close the form.

The truck analysis view appears in which you can select the best truck solution.



There is however a problem a problem as the number of pallet in the truck reaches 52, the number of cases reaches 2912 and the total load (39.124 kg) exceeds the authorized trailer load of 24 tons.


Generate report


In the document explorer tree, right click the solution element. In the context menu, select the "Generate report for ..." command with the MS Word icon clip_image038.

The software generates a Word ML report and launches MS Word. Let word convert this file from XML Document.


Report file can be downloaded here: [file:Matches.doc]

Save your project


Either click the menu File>Save or the toolbar button "Save file".

A "Save as..." dialog appears and in which you can enter a file name such as "Matches.stb".


4. Conclusion

The best case found is:

Case dimensions








It allows building the following pallet:

Number of cases


Total weight (kg)


Height (mm)



However, there is a problem since truck load reaches 39.124 tons loads which exceeds the trailer maximum load of 24 tons.

This should be corrected in the next software release.

Last edited Apr 20, 2011 at 12:27 PM by fgasnier71, version 6