10. Instruction sheet

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10.1 Instruction sheet 1: standardisation and unitisation

Objectives:

1. To get familiar with the use of standardisation and unitisation in packaging, using a model on scale(1:10).
2. To identify the advantages of standardised as compared to non-standardised systems.

Materials:

• 1Plank, size 12 cm x 10 cm x 1 cm
• 15 Blocks, size 6 cm x 4 cm x 3 cm (bottom - 6 cm x 4 cm)
• 8 Blocks, size 5 cm x 3 cm x 3 cm (bottom - 5 cm x 3 cm)
• 10 Blocks, size 4 cm x 3 cm x 3 cm (bottom - 4 cm x 3 cm)
• 6 Blocks, size 5 cm x 4 cm x 3 cm (bottom - 5 cm x 4 cm)
• 20 Blocks, size 4 cm x 3 cm x 1.5 cm (bottom - 4 cm x 3 cm)
• 8 Blocks, size 5.08 cm x 3.30 cm x 1.84 cm (bottom - 5.08 cm x 3.30 cm)

Most of these blocks can be cut from one length (210 cm) of a plank with the size of 3 cm x 4 cm. Further to that a length of 12 cm with size 10 cm x 1 cm and a length of 50 cm with size 3 cm x 3 cm are needed. For the last 8 blocks on the list it is suggested to take a length of 50 cm with size 4 cm x 2 cm and to plain this plank to size 3.30 cm x 1.84 cm before cutting into 8 blocks.

Clearly mark the blocks with 'BOTTOM' and 'TOP'. Mark the cubes on one side of each cube with their size, being 10 times the scale size. For example 60 x 40 x 30.

FIG.1.Mixed load layer concept

FIG.2.Stacking pattern per layer

Instruction:

1.

1. Place the plank 120 x 100 mm in front of you.
2. Place one layer of cubes size 60 x 40 x 30 (bottom down) on the plank in such a way that they exactly fit on the plank.
3. Draw the top view of the boxes on the plank in Figure 1.
4. Place a second layer using the cubes with size 60 x 40 x 30 (bottom down) on top of first layer in such a way that they exactly fit on the plank and that they consolidate the first layer.
5. Draw the top view of the boxes on the plank in Figure 2.
6. Place a third layer using the cubes with size 60 x 40 x 30 (bottom down) on top of the second layer in such a way that they exactly fit on the plank and that they consolidate the second layer.
7. Draw the top view of the boxes on the plank in Figure 3.
8. Clear the plank.

FIG.1.FIGURE A

2.

1. Place one layer of cubes with size 60 x 40 x 30 -(bottom down) on the plank in such a way that the blocks exactly fit on the plank.
2. Draw the top view of the boxes on the plank in Figure 4. .
3. Place a second layer using the cubes with size 50 x 30 x 30 (bottom down).
4. Draw the top view of the boxes on the plank in Figure 5.
5. Place a third layer using the cubes with size 40 x 30 x 30 (bottom down).
6. Draw the top view of the boxes on the plank in Figure 6.
7. Place a fourth layer using the cubes with size 50 x 40 x 30 (bottom down).
8. Draw the top view of the boxes on the plank in Figure 7.

FIG.2.FIGURE B

3.

1. Remove the second, third and fourth layer.
2. Place a second layer using the cubes with size 40 x 30 x 15 (bottom down).
3. Draw the top view of the boxes on the plank in Figure 8.
4. Place on the second layer a third layer using three (3) cubes with size 60 x 40 x 30 (bottom down), four (4) cubes of size 40 x 30 x 15 (bottom down) and four cubes of 40 x 30 x 15 (on the side).
5. Draw the top view of the boxes on the plank in Figure 9.
6. Clear the plank.

FIG.1.FIGURE C

4.

1. Place a layer of cubes size 5.08 x 3.30 x 1.84 cm (bottom down) on the plank. The cubes must fit within the boundaries of the plank.
2. Draw the top view of the boxes in Figure 10.
3. How many cubes could be placed on the plank?

The surface of the plank is 120 cm x 100 cm =12,000 cm² . The surface of a banana box is 50.8 cm x 33.0 cm = 1,676 cm² . Thus the banana boxes together, as you placed them on the plank will occupy:

........ cubes x 1676 cm² =…………………cm².

The efficiency is:

Surface all boxes

…………cm²

…..……………. x 100% =….………….x 100% = ………… %

Surface plank 12,000 cm

10.2 Instruction sheet 2: cost calculation packaging

Objectives:

1. To become familiar with cost calculations for different types of packaging.
2. To demonstrate the difference between purchase cost and running cost.

Remark:

The figures and data in this example are fictitious and may need modification to a real life situation.

Information:

A marketing board in the East Caribbean wants to introduce a new type of field crate. The crate will be used to transport the produce from the field to the packing shed.

The marketing board considers two crates, e.g. a locally manufactured wooden crate and an imported plastic stack crate, both crates are the same size 60 x 40 x 30 cm.

The following general data are available:

• 1 US$ - 2.70 EC$.
• The average value of the produce per trip amounts EC$ 25.00.
• The tax and duty on imported crates is 40% of the F.O.B. and freight costs. The duty on locally manufactured goods is EC$ 1.00.
• The distribution cost of a crate by the marketing board is EC$ 1.00.
• It is advised to use a liner at a cost of EC$ 0.75 per trip.
• The transport cost per trip (full from the field to the packing shed and empty from the packing shed to the field) amounts EC$ 2.00.
• The handling cost of the crate in the packing shed (accepting, storage and re-issuing) is estimated at EC$ 0.25 per trip.

Extra data on the wooden crate:

• Cost F.O.B. of one wooden crate is EC$ 12.00. .
• Transport cost to the packing shed is EC. 0.25 per crate.
• Cleaning of this wooden crate costs EC$ 0.50 per trip
• Estimated loss of produce caused by using the wooden crate (splinters, cracking of wood, infestation by fungus in wood) is estimated at 5% of the value of the content.
• It is expected that each crate can survive 20 trips, but that EC' 2.00 is needed over the lifetime of the crate to do some minor repairs (nails, new planks, etc.)

Extra data on the plastic crate:

• Cost F.O.B. of one plastic crate is US$ 5.17 and the transport cost, including insurance and freight will amount US$ 1.50 per crate.
• There will be no repair cost.
• It is estimated that the crate will survive 40 trips.
• Cleaning of this crate costs EC$ 0.25 per trip.
• The estimated loss when using this plastic crate are 2% of the value of the content.

Instruction:

a. Hake a calculation of the running costs of each of the crates per trip. An empty sheet is attached to do the calculations.

b. Fill in the following table:

c. Which other costs or financial losses does the farmer, trader or consumer have to take into consideration when comparing the cost of different types of packages?

1………………………………………………………………………………………………………………

2………………………………………………………………………………………………………………

3………………………………………………………………………………………………………………

4………………………………………………………………………………………………………………

5………………………………………………………………………………………………………………

6………………………………………………………………………………………………………………

7………………………………………………………………………………………………………………

8………………………………………………………………………………………………………………

9………………………………………………………………………………………………………………

10…………………………………………………………………………………………………………….

Currency used : Exchange rate : 1 US$ -=

Date : .../.../19…

Description crates: Crate 1: ...................

Crate 2: ...................

Crate 3: ...................

DESCRIPTION DIRECT COSTS CRATE 1 CRATE 2 CRATE 3

_____________________________________________________________________

a. Purchase cost F.O.B

b. Freight and insurance

c. Purchase cost C.I.F. (a + b)

d. Tax/duty

e. Purchase wholesale (c + d)

f. Distribution coat

g. Purchase cost user (e + f)

h. Total repair cost over life time

i. Total cost (g + h)

j. Average total runs

k. Crate cost per run (i /j)

l. Cost liner material

m. Cost label

n. Ready for shipment (k +l + m)

o. Handling cost, e.g. (un)loading

p. Transport cost (field to shed)

q. Cost delivered at shed (n +o +p)

r. return freight cost empty crate

s. Cleaning cost

t. Extra cost per run (q+ r+ s)

_____________________________________________________________________

u. Market value produce per crate

v. Estimated lose of produce (%)

w. Value estimated lose (u*v/100)

x. Total cost per trip (t + w)

_____________________________________________________________________

10.3 Instruction sheet 3: choice of packaging

Objectives:

1. To become familiar with the different characteristics of packaging.
2. To learn to decide which package to use and to invest in.

Remark:

This example is only indicative and should be adapted to each individual situation.

Information:

An exporter would like to introduce standard crates to the farmers who supply the produce (mainly citrus, mango, avocado, sweet potato and eddoe). The exporter intends to import or manufacture the crates and sell them to the farmers without any profit. Most of the farms can be reached by small trucks. The following options are to be considered:

1. A woven basket without cover. Price EC$ 5.00, can be used for 10 trips, height: 80 cm, diameter: 70 cm and volume is 150 liter.
2. A wooden crate. Price EC$ 20.00, for 20 trips, size 60 x 40 x 30 cm and volume is 60 liter.
3. A plastic stack crate. Price EC$ 30.00, suitable for 50 trips, size 60 x 40 x 30 cm and volume 60 liter.
4. A plastic stack-nest crate. Price EC$ 65.00, for 50 trips, size 60 x 40 x 30 cm and volume 55 liter.

Instruction:

a. Give your personal preference (1, 2, 3 or 4) for each of the four crates.

Preference:

• Woven basket ...
• Wooden crate ...
• Plastic stack crate ...
• Plastic stack-nest crate ...

b. Fill in, on the attached empty form, the priority you give to each of the group of characteristics (column 1) and to each characteristic (column 2). The total of each of the columns must be 100.

c. Give values to the characteristics (column A) for each of the four different types of packaging. ++ =excellent; + = good; o = fair; — = unsuitable; — — = extremely unsuitable.

d. Multiply the priorities (column 2) with the values (column A) of each of the crates and note down the result in column B. For example 8 times (++) - 16 +, 4 times (0) - 0. etc.

e. Add up column B for each of the crates.

f. Write the results for the different crates (as found in e.) behind the personal preference in a.

Does your personal preference correspond with the results in column B? If not, what may be the reason?

g. Compare column B of the two crates with the highest total and note the characteristics that differ most for the two crates.

CHECKLIST

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