This document provides details on packaging design reviews for several products. It includes exploded views of packaging assemblies, test data from package drop tests, proposals to reduce package sizes by simplifying designs or using alternative materials, and specifications for palletization. Key recommendations include replacing EPS foam with corrugated inserts or R-Mer foam to reduce box sizes, consolidating accessories into a single box, and improving pallet stacking efficiency.
28. Speaker
A cutout on the bottom insert
accommodates the mounting tab
Corrugated Insert of the speaker and secures it in place
Boxed AC Adapter
Boxed AC Adapter is held in
place by design features
that are part of the bottom
insert
Corrugated Box
Folded flaps hold and protect the
speaker at the top
3-30-09
31. Materials Comparison
@ 3 months storage
OBSERVATION:
Note the performance of 275-Mullen,
which is the current material of the
current packaging, that it falls short of
being able to be stacked 4 loads high.
RECCOMENDATION:
Appropriate material choices can be
determined by the “Loads
High” column on this page. Any sited
materials that makes 4 loads high or
better and once correlated with
estimating we can determine an Materials Comparison
appropriate choice vs. the current @ 1 month storage
material. There are quite a few
depending on what’s available and
meets their budget requirement in
both single wall and double wall.
And/or Mullen vs. ECT.
BOSE MUSIC SYSTEM
5-6-09
35. Laptop1 | Laptop Pack – SOP
R)&-!S8</&' F %,;(
1//!G)H
O)/!B6&*
R)&-!S8</&' F T7?>(
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36. Laptop1 | Laptop Pack – SOP
STEP #1
Assembled the foams with
laptop.
U
37. Laptop1 | Laptop Pack – SOP
STEP #2
Insert laptop with foam in
to the gift box.
V
38. Laptop1 | Laptop Pack – SOP
STEP #3
Place Power Cord and
AC Power Adapter in to
the Acc Box.
STEP #4
Insert Acc Box in to the
gift box.
W
39. Laptop1 | Laptop Pack – SOP
STEP #5
Place CDs and
Documents on to the Doc
Tray.
STEP #6
Slide the Doc Tray in to
the gift box.
X
40. Laptop1 | Laptop Pack – SOP
STEP #7
Secure of all flaps are
properly tacked.
STEP #8
Place SECURITY LABEL centered on
the gift box in area indicated in image
•Security label wraps from vertical
gift box face to bottom face
Y
41. Laptop1 | Laptop Pack – SOP
STEP #9
Stack 66 per pallet as
Shown. 1134.4
Take note that all labels
point out
996.9 1117.6
Dell 1200 X 1000 1200.0x1000.0x120.0
Carton Carton UnitLoad
(ID) (OD) (Incl. Pal)
Ln: 497.56mm 498.47mm 1117.6mm
Wd: 100.69mm 101.60mm 996.9mm
Ht: 335.85mm 338.14mm 1134.4mm
Grs: 0.00g 13.000kg
Cube: 16.825l 17.1l 1.2639m3
Height Vert
Carton: 66
Area Efficiency: 92.8%
Cubic Efficiency: 87.6%
Cases per layer: 22
Layers/load: 3
Pattern: Column
!Z
42. PC Desktop | POR
• Corrugated Regular Slotted Container (RSC)
• External Dimensions: 22” x 12” x 24”
• Test/Flute: 51 ECT BC Double Wall
44. PC Desktop | TEST DATA
PC Desktop PC Drop Test
Date: 10/03/09
Package Weight: 41.4 lb
Drop Height: 30"
REV: 0 (POR) REV: 1
Orientation G !V G !V
1 Bottom Corner (2-3-5) 12.39 166.92 18.24 150.35
2 Shortest Edge radiating (3-5) 34.84 184.77 25.06 158.39
3 Next Longest (2-5) 19.31 214.9 42.45 211.86
4 Next Longest (2-3) 23.61 215.2 63.10 188.10
5 Flat Face small Face 1 27.85 208.42 29.33 227.75
6 Flat Face small Face 3 35.02 227.36 42.77 221.83
7 Flat Face medium Face 5 40.87 231.73 57.47 216.51
8 Flat Face medium Face 6 40.43 203.14 39.36 229.63
9 Flat Face Large Face 2 38.83 208.75 58.92 140.64
10 Flat Face Large Face 4 32.96 222.56 117.02 273.77
Max 40.87 117.02
Min 12.39 18.24
* Test unit was shipped to us and as such is preconditioned. Our test results reflect that by slightly higher readings than we would expect to see in a non
shipped condition.
45. PC Desktop | POR
* Assumptions: 48” x 40” pallet with a max height of 53” (including the pallet)
47. PC Desktop | Proposal
• Reduce the size and design of the foam end caps
• Reduce the size of the box
• Place all accessories and documentation in 1 common place; eliminating some packaging components
48. PC Desktop | Proposal
1. Change the master carton to single wall and
change the style to an FOL (Full Overlap)
2. Move all accessories to 1 box and place it at
the top of the package
49. PC Desktop | Proposal – new accessory box details
This proposed design eliminates the need for a bag and combines the storage
of the documents, CD, keyboard, mouse and cords in one location.
The consumer experience is also slightly modified with an aim to simplifying
the removal of accessories from the box and creating 1 centralized location for
everything the consumer will need to start using their new PC.
A reduction of packaging materials and waste is also achieved with this new
design.
50. PC Desktop | Proposal
* Proposed new design allows for an additional 4 units per pallet, creating a 25% improvement over the POR package.
57. PRINTER PS Plus | Option #1 - Replace EPS foam with a corrugated Insert
•12% smaller box
• Environmentally friendly package
58. PRINTER PS Plus | Option #1 - Replace EPS foam with a corrugated Insert
Printer
Top flaps fold over to make the
paper tray and accessory storage
area.
Paper Tray
D/C Insert
Gift Box
59. PRINTER PS Plus | Option #1 - Replace EPS foam with a corrugated Insert
* 18 cartons per pallet = 12% improvement when compared to POR
60. PRINTER PS Plus | Option #2 R-Mer FOAM
Proposal: Change existing EPS mold tooling to allow the use of an alternate foam material which will create an opportunity to reduce the size of the box by !”. For
example, the use of “R-Mer” co-polymer instead of EPS foam.
Surface area of POR end caps - EPS foam configuration
EPS foam density is 1.3 psf
Bottom = 24.07 sq. in.
Back = 16.88 sq. in.
Front = 19.82 sq. in.
Reduced by !”
Top = 21.75 sq. in.
L Side = 20.25 sq.in.
R Side = 21.56 sq.in.
Avg. = 21 sq. in.
21 sq. in./ 19.2 lbs. = 1.09 psi
* Printer weight is 19.2 lb.
61. PRINTER PS Plus | Option #2 R-Mer FOAM – G level comparison
12% reduction in G force
Option 2
Orientation Drop (POR) EPS 1.3 PCF R-MER 1.3 PCF
1 Bottom Corner (2-3-5) 36.89 32.46
2 Shortest Edge radiating (3-5) 60.31 53.07
3 Next Longest (2-5) 54.39 47.86
4 Next Longest (2-3) 44.68 39.32
5 Flat Face small Face 1 69.63 61.27
6 Flat Face small Face 3 98.73 86.88
7 Flat Face medium Face 5 90.56 79.69
8 Flat Face medium Face 6 127.48 112.18
9 Flat Face Large Face 2 83.64 73.60
10 Flat Face Large Face 4 103.58 91.15
Based on the shown cushioning curve
data we can see that by using a 1.3 pcf
R-Mer foam in place of the current EPS
solution (shown as a blue dotted line)
we can apply the same density of R-Mer
product and realize an approximate 12%
improvement in product protection.
The red arrow shows the EPS curve at
approximately 12% higher G rating than
the R-mer with the existing static loading
of 1.09 psi.
* Test unit was shipped to us and as such is preconditioned. Our test results reflect that by slightly higher readings than we would expect to see in a non shipped condition.
62. PRINTER PS Plus | Option #2 R-Mer FOAM
18 cartons per pallet = 12% improvement when compared to POR.
63. PRINTER PS Plus | Option #3 Molded pulp end cap
• The use of molded fiber end caps may allow a reduction on the overall size of the package
• Molded pulp end caps are more environmentally friendly than EPS
Molded Pulp End cap (Right)
Molded Pulp End cap (Left)
* Molded pulp can be composed of fibers from Bamboo, Rice Hull, Sugar Cane, Paper, or Palm
65. CUS LCD Single Pack | Foam Option
1.)Slide die cut back bars into place
2.)Slide 1 set of foam end caps onto LCD
clamshell
3.) Place in to die cut box
4.) Note location of labels
66. CUS LCD Single Pack | Foam Option
1.)Slide die cut back bars into place
2.)Slide 1 set of foam end caps onto LCD
clamshell
3.) Place in to die cut box
76. V17BACKPACK-3.ai 12/11/2008 10:44:51 AM
!"
Manufactured in China
Distributed by:
Circuit City Stores, Inc.
9950 Mayland Drive
Richmond, VA 23233
www.vergeproducts.com
or call 888.319.9464
V17BACKPACK
4 00000 00175 3
812 Backpack
With Laptop Compartment
Padded compartment for laptops up to 17"
Durable nylon construction fits your active
lifestyle
Large pockets provide maximum capacity
and organization
Padded shoulder straps for back support
and comfort
Reinforced ergonomic carrying handle
Side mesh pockets can hold water bottles
or extra gear
Luggage trolley strap included
Great for use at school, the office, or on
the road
812 Backpack
With Laptop Compartment
77. OPTION 3
720p LCD HDTV
19” with built-in DVD player
S1900U
7
720p LCD HDTV 7
720p LCD HDTV 7
720p LCD HDTV 7
720p LCD HDTV
19” wit built-in DVD player
with
S19
S1900U 19” w
with built-in DVD player
S1
S1900U
19” wi
with built-in DVD player
S19
S1900U 19” w
with built-in DVD player
S1
S1900U
• Panel Resolution: 1366*768
?”
• Screen Size: 18.5" diagonal
• Aspect Ratio: 16:9
HDMI CONNECTIVITY
CONNECTIVITY
C
• Contrast Ratio: 1000:1
For a High Definition, all-digital
• Response time: 5ms
audio and video connection over
a single cable. (HDMI cable not included)
• Power Rating: 120v 60hz 16:9 widescreen
• Vesa Wall Mount Compatible
• resolución del panel: 1680 X 1050
16:9 widescreen Spanish
• cociente de aspecto: 16:10
PC INPUT • cociente del contraste: 700:1
Connect a laptop or desktop computer • tiempo de reacción: 8 MS
?”
Digi Tuner
Digital
• grado de energía: 120v 60hz
to your SENS TV using a VGA cable. ?” • vesa wall montaje compatible
• reproductor de DVD incorporado
disc tu
tuner Spanish
BUILT-IN ATSC DIGITAL TUNER Package includes:
Allows access to over-the-air HD and 19" TV Quick Installation Guide Stand Manual
Remote control (includes 2 AAA batteries)
Standard Definition programming.
Inputs:
2 HDMI Inputs
WALL-MOUNTABLE LCD TV
Component video Input 2x HDMI PC audio input RF Input
digital HDMI Spanish
Standard VESA mounting pattern provides Composite video input USB port PC video input S-Video Input
for viewing flexibility in most rooms. Headphone jack output Analog audio input RCA audio
USB INPUT AV OUT
Wall Mountable
wall mountable Spanish
VIDEO AUDIO AUDIO VIDEO AUDIO
OUT OUT IN IN IN
R L TV
Allows you to view photos from a USB HDMI IN PC IN R R
ANTENNA
HEADPHONE
OUT
thumb drive. L L
Let firedog install it. Y P PR S-VIDEO
SM B
VGA AUDIO
COMPONENT AV IN
PC combatible
We offer convenient
ENERGY STAR CERTIFIED night or weekend appointments. VIDEO IN
1.800.firedog | firedog.com
SENS has adopted energy efficient practices available at Circuit City
PC combatible Spanish
and understands the importance of providing Recommended Accessories:
energy efficient products. Nexxtech Ultimate HDMI cable for high-definition connections
Verge Small Flat-Panel Wall Mounts
S1900U
4 00000 00247 7
19” 720p LCD HDTV
OPTION 4 720p LCD HDTV
19” with built-in DVD player
S1900U
7
720p LCD HDTV 7
720p LCD HDTV 7
720p LCD HDTV 7
720p LCD HDTV
19” wit built-in DVD player
with
S19
S1900U 19” w built-in DVD player
with
S1
S1900U
19” wi built-in DVD player
with
S19
S1900U 19” w
with built-in DVD player
S1
S1900U
• Panel Resolution: 1366*768
?”
• Screen Size: 18.5" diagonal
• Aspect Ratio: 16:9
HDMI CONNECTIVITY
CONNECTIVITY
CTIVIT
• Contrast Ratio: 1000:1
For a High Definition, all-digital
• Response time: 5ms
audio and video connection over
a single cable. (HDMI cable not included)
• Power Rating: 120v 60hz 16:9 widescreen
• Vesa Wall Mount Compatible
• resolución del panel: 1680 X 1050
16:9 widescreen Spanish
• cociente de aspecto: 16:10
PC INPUT • cociente del contraste: 700:1
Connect a laptop or desktop computer • tiempo de reacción: 8 MS
?”
Digi
Digital Tuner
• grado de energía: 120v 60hz
to your SENS TV using a VGA cable. ?” • vesa wall montaje compatible
• reproductor de DVD incorporado
disc tuner Spanish
tu
BUILT-IN ATSC DIGITAL TUNER Package includes:
Allows access to over-the-air HD and 19" TV Quick Installation Guide Stand Manual
Remote control (includes 2 AAA batteries)
Standard Definition programming.
Inputs:
2 HDMI Inputs
WALL-MOUNTABLE LCD TV
Component video Input 2x HDMI PC audio input RF Input
digital HDMI Spanish
Standard VESA mounting pattern provides Composite video input USB port PC video input S-Video Input
for viewing flexibility in most rooms. Headphone jack output Analog audio input RCA audio
USB INPUT AV OUT
Wall Mountable
wall mountable Spanish
VIDEO AUDIO AUDIO VIDEO AUDIO
OUT OUT IN IN IN
R L TV
Allows you to view photos from a USB HDMI IN PC IN R R
ANTENNA
HEADPHONE
OUT
thumb drive. L L
Let firedog install it. Y P PR S-VIDEO
SM B
VGA AUDIO
COMPONENT AV IN
PC combatible
We offer convenient
ENERGY STAR CERTIFIED night or weekend appointments. VIDEO IN
1.800.firedog | firedog.com
SENS has adopted energy efficient practices available at Circuit City
PC combatible Spanish
and understands the importance of providing Recommended Accessories:
energy efficient products. Nexxtech Ultimate HDMI cable for high-definition connections
Verge Small Flat-Panel Wall Mounts
S1900U
4 00000 00247 7
19” 720p LCD HDTV
78. 4:45 pm, Jul 18, 2008 11:10 am, Jul 21, 2008
080031-V37TLTMT-7-9-08.ai 7/18/2008 4:43:48 PM
Strong & Sleek Parts Included
Constructed of steel, this low-profile tilt mount places your All mounting hardware
TV just 3" from the wall.
Bubble level
Versatile
The tilt function of this mount allows you to adjust the vertical
angle from -5° to +15° to achieve the best viewing angle. Tools Needed
Stud finder
Wall
Easy to Use
TV
Arms with automatic safety locks ensure simple, but secure installation. Drill
Worry-Free Installation 3/16" (5 mm) wood bit or
All mounting hardware including a magnetic bubble level is included. 3/8" (10 mm) masonry bit
Maximum Compatibility 1/2" (13 mm) wrench
This mount fits TVs with VESA 400 x 300 mounting pattern.
Phillips screw driver
Tilt TV Mount 23" to 37"
Supports 23" - 37" TVs
Holds up to 88 lb (40 kg)
Wall
Wall
TV
TV
Self-locking safety arms
Tilt angle -5° to +15°
Tilt TV Mount 23" to 37"
Tilt TV Mount 23" to 37" Soporte De TV Inclinable
For more information call
Verge customer service
at 1.888.319.9464 or log on to
www.vergeproducts.com
Manufactured in China
Tilt TV Mount 23" to 37"
Distributed by:
Circuit City Stores, Inc.
9950 Mayland Drive
Richmond, VA 23233
C
V37TLTMT
M
4 00000 00063 3
Y
CM Soporte De TV Inclinable
MY
Destornillador Phillips Ángulo de inclinación -5° a +15°
CY
Llave inglesa de 1/2" (13 mm)
o de mampostería 3/8" (10 mm)
Broca de madera de 3/16" (5 mm) automática
Taladro Brazos de seguridad con traba
Wall
TV
CMY
Detector de clavos
Herramientas necesarias
Sostiene hasta 88 lb (40 kg)
Nivel
K Todo el material de montaje
Soporta TV de 23" a 37"
Incluye
Tamaño VESA: 400 x 300
FIRE DOG GREEN
OVERALL MAIN COLORS:
1.) THE FIREDOG GREEN IS PANTONE 376C
NOTES: 1.) PANTONE PROCESS BLACK
2.) PANTONE 1505 C2
PRINTER SHOULD USE THAT COLOR AS A TARGET
1.) STRUCTURAL DESIGN #: 08GPS0031
BUT USING CMYK.
2.) 2-COLOR + UV COATING COLORS SHOWN HERE ARE FOR REFERENCE ONLY
PRODUCTION MUST MATCH APPROVED COLOR
THE GREEN SHOWN HERE IS FOR REFERENCE ONLY
TOLERANCE SETS
AND SHOULD BE IGNORED.