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)

Height(mm)

Weight (kg)

clip_image001

78.5

56.0

31.5

0.043

 

Case constraints

Number of boxes per case

150

Maximum dimensions

Length (mm)

Width (mm)

Height (mm)

600

600

600

 

Cardboard thickness (mm)

4

Number of thicknesses

in length direction

in width direction

in height direction

2

2

4

 

Estimated case weight (kg)

0.8

 

Maximum pallet height (mm)

1320

 

Pallet

Pallet EUR2

Length (mm)

Width (mm)

Height (mm)

Weight (kg)

clip_image003

1200

1000

144

30

 

 

Truck trailer

 

 

Length (mm)

Width (mm)

Height (mm)

clip_image005

13700

2480

2650

 


 

3. Solving with StackBuilder

 

Launch StackBuilder

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

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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.

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The document explorer now shows your project.

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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.

 

clip_image019

 

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.

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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.

clip_image029

 

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.

clip_image031

 

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

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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"

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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.

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Note:

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.

clip_image040

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

Length

Width

Height

288

243.5

331

 

It allows building the following pallet:

Number of cases

56

Total weight (kg)

752.40

Height (mm)

1296

 

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

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