Packaging Processes

Packaging overview

The Packaging process model, located in the Other Secondary Processes process group, enables estimation of expenses related to both semi-automated and manual packing of components into boxes for shipping or transport to another facility. If you have licensed the Packaging module, packaging processes are available to be included in all other Process Group routings, so that you can estimate the complete cost of manufacturing and packaging a part or assembly.

The Packaging routing available in the aPriori starting point Digital Factories includes the following processes:

  • Carton Forming

  • Pack and Load

  • Carton Sealing

The Carton Forming process estimates the time and cost to unfold a flattened carton into an open, three-dimensional state so it can contain components, and includes the cost of the carton itself. The Pack and Load process estimates the time and cost of placing components into the opened carton. It provides options to specify bagging and bubble-wrapping of component and includes the cost of bags and bubble wrap if used. The Carton Sealing process estimates the time and cost of closing and securing the carton.

Packaging costs are amortized over the total number of components contained in a carton. The size of the carton and the number of components contained in a carton both are automatically computed, but you can override them to match a specific situation.

aPriori by default will select the smallest available carton (from a table of available carton sizes) that is larger than the part (or a bag of parts, if bagging is used). aPriori then determines the number of parts/bagged set of parts that will fit in that carton; to determine this number it employs a simplified “bin nesting” algorithm that utilizes the rectangular bounding box of the part, rather than a true-part-shape 3D nesting algorithm. Process setup options are provided to allow users to override both automatically-computed carton and bag sizes and the number of items in a carton or bag, as well as many other inputs that affect cost estimates.

Packaging machines

The aPriori starting point Digital Factories contain multiple Carton Forming machines, Pack and Load machines, and Carton Sealing machines (both automated and semi-automated models). There is also a “manual” instance of each machine type, to accommodate workflows that perform aspects of the packaging process using manual labor rather than automated machinery.

In each case (Carton Forming, Pack and Load, and Carton Sealing), aPriori will select the first machine that can physically accommodate the component and its chosen package size, that is also capable of running at a desired rate (cartons per unit time) if you specify one. The manual machine instance automatically will be chosen when estimating the cost of packaging large components which exceed the size limits for the semi/automated machines.

If you feel another machine better represents the actual packaging environment, you can manually select a different machine using the Edit Machine Selection window which lists the properties of all machines available at the facility. For information on how to select a different machine, see the "Selecting a machine for an operation" section of the aPriori Professional User Guide.

Packaging process routings

Packaging processes (as well as Surface Treatment and Heat Treatment processes) are contained in secondary process groups. That is, these processes are applied in conjunction or subsequent to the primary manufacturing processes that are used to manufacture a part. As such, they are not available for selection when indicating the primary process group (for example, in the Production Info window or in the Select Primary Process Group window). Instead, you must Edit the process routing to include Packaging processes; they are not assigned automatically by aPriori .

To include packaging processes in a routing

  1. In the Manufacturing Process pane, click the Edit menu and choose Routing Selection…

  1. The Routing Selection window will appear. The last node of each routing is the Other Secondary Processes node. For the routing level of interest, click the + symbol to expand the Other Secondary Process node so that the top-level Packaging node is displayed.

  2. Right-click on the Packaging node and select Include from the popup menu.

    Note: This automatically includes the Carton Forming, Pack & Load, and Carton Sealing processes organized under the Packaging node.

  1. To remove Packaging process from a routing, right-click on the Packaging node and select Exclude or Let aPriori Decide from the popup menu.

Packaging process setup

The Packaging processes allow you to provide numerous additional inputs about how the component is packaged, which can have an impact on cost estimates. The Packaging process setup options all are accessed by right-clicking on the Processing node, not on the individual Carton Forming, Pack & Load, or Carton Sealing processes. This is because many of the inputs affect all three processes.

The Packaging process setup options window displays some automatically-computed results and provides many options:

  • Include Bagging - Indicate whether components are placed in bags prior to being placed in the carton

  • Include Bubble Wrap – Indicate whether bubble wrapping is used

  • Components Per Bag – defaults to 1, but user can specify the number, if different

  • An automatically computed “Packed Unit Size”, where a Unit is defined as a component or a bag of components, if bagging is used.

  • Overrides for the automatically-computed packed unit size (Length, Width, and Height overrides)

  • Carton Size and Bag Size - overrides for the automatically-selected carton size and bag size, respectively

  • Carton Cost – an override for the standard (catalog) cost of the selected carton

  • Bubble-Wrapping Size/Cost – an override for the standard unit cost of bubble wrap material

  • Units per Carton – an override for the automatically-computed number of units per carton

  • Carton Forming Rate – an override for the default carton forming rate (as specified in the machine table for the selected machine)

  • Carton Sealing Rate – an override for the default carton sealing rate (as specified in the machine table for the selected machine)

  • Pack & Load Time – an override for the automatically-computed loading time for a unit

  • Bubble Wrapping Time – an override for the automatically-computed bubble wrapping time

Packaging costing details

The Packaging processes use the following costing rules:

  • If Packaging is included in a primary process group routing, then the costs associated with the packaging processes are computed by the Packing cost model and combined with the primary process group costs, and any other secondary processes (Heat Treatment and Surface Treatment) to produce a total manufacturing process cost.

  • Material costs associated with packaging processes, such as the cost of cartons, bags, and bubble wrap, will not appear in the Material Cost field of the cost taxonomy (which is displayed in various places through aPriori , such as on the Cost Summary and Part t Details tabs as well as various reports). Instead, these costs will appear as Additional Direct Costs.