Electronic Parts/Guidelines - infoHouse

The cost differential between disposable and reusable containers is often smaller with large parts,
than with small parts. With a high number of reuses, this makes the total materials cost very low.
Large parts are often good candidates for warehouse on wheels (WOW) or kanban on wheels
(KOW) inventory management programs. When parts suppliers are not close, just in time (JIT)
dellvery programs are more easily justified with larger parts. The larger parts often are the more
expensive and require the most amount of storage space. So, eliminating these parts from ware-
house storage, usually results in significant inventory savings. Frequent delivery and no ware-
house storage also reduces the number of reusable containers needed and results in low or free
return Shipping costs, especially when the vendor's trucks are returning empty.
lnventwy Control: Consider inventory management practices, when evaluating and designing reus-
able containers.
Be sure reusable containers hold the right number of parts to match inventory disbursement or
manufacturing kanban quantities.
Where inventory control is poor or when inventory levels (or part demands) are likely to vary signif-
icantly, keep the reusable container or packaging cost very low, to minimize costs to replace lost
items or to buy new ones. Also, keep the design of the reusable item very simple, so procurement
lead-times will be very short. Durability and high reuse may have to be sacrificed, so replacement
or new items will be inexpensive and easy to get.
Bulk n. Unlt Packs: Bulk packaging applications are gWd candidates for reusable containers. Look
for single unit packages that currently use several different materials in the package design. For
example, ESD sensitive and fragile components and assemblies (e.@, small disk drives, cards and
boards) shipped by suppliers and component plants are often individually packed with conductive bags,
foam WShiOning, and fiberboard cartons. These individual and disposable packages can sometimes
be replaced with bulk (holding many parts) containers made of conductive COrrUgated fiberboard with
anti-static foam inserts.
Other Pasign Facton: In addition to the design factors listed above, the following design consider-
ations should be made:
Design Style B Reuse: Select container and packaging styles that lend themselves to high reuse.
For example, HSC 8 cap style containers are better suited to multiple openings and closings, than
RSC style containers. They also can use closures other than tapes that may damage the con-
tainer (e.g., tape removal may peel away liner board).
Easy Use: Design reusable containers and packaging to allow easy packing, Unpacking and
repacking. This will help to ensure parts are properly protected and packaging Items are not
misused or misplaced. Avoid jig-saw puzzle complexity. If a reusable package is used only occa-
sionally by individuals (e.9.. IBM Customer Engineers using field replacement part packages for
park return) minimize complexity so the package can be easily reassembled and reused, without a
high degree of packing expertise. Where possible, the packing process should be no more than
three steps -open, place (the part), and closelseal.
Cushioning Materials: Avoid foam cushions made with low density materials, especially foam-in-
place urethanes and expanded polystyrenes. These materials will easily break apart and com-
-press with high reuse. The shock protection ability will then be seriously degraded. CUShiOning
materials selected should be able to provide adequate shock protection, after many drops and
reuses. As a general guide, for each reuse, a reusable cushion should be able to pass the test
requirements of IBM Corporate Specification, C-H 1-9711-005, Packaged Product Tests. For
example, the test specification requires eight (8) drops - one on each package face, one edge and
one corner. If ten reuses are planned for a cushion, the cushion should be tested with a total of
eighty (80) drops from the required drop height.
Component Replacement: Design reusable containers so worn or damaged components can be
easily replaced, without having to throw away the entire container. Also keep component designs
Material Redudion and Reusable Packaging Guidelines 49