A Comparison of Hand Phone Primary Packaging By Using Pugh Method (Case Study)

Transcription

1 UNIVERSITI TEKNIKAL MALAYSIA MELAKA A Comparison of Hand Phone Primary Packaging By Using Pugh Method (Case Study) Thesis submitted in accordance with the partial requirements of the Universiti Teknikal Malaysia Melaka for the Bachelor of Manufacturing Engineering (Manufacturing Design) By Nuranisha Binti Mat Ghani Faculty of Manufacturing Engineering May 2007

2 UTeM Library (Pind.l/2007) UNIVERSITI TEKNIKAL MALAYSIA MELAKA BORANG PENGESAHAN STATUS TESIS* JUDUL: A COMPARISON OF HAND PHONE PRIMARY PACKAGING BY USING PUGH METHOD(CASESTUDY) SESI PENGAJIAN: 2/ Say a NURANISHA BT MAT GHANI mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan (.../) D SULIT D TERHAD [i] TIDAK TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) Disahkan oleh: (TA~ PENULIS) Alamat Tetap: No 47, Rumah Keretapi, Jalan Stesen, 16200, Tumpat, Kelantan. Tarikh: 14 MEl 2007 Cop Rasmi: SURIATI BINTI AKMAL Pensyolfah F akulti KeJuruteraan Pembuatan Universitt Tekmkal Malaysta Melaka Karung lerkunci Ayer Keroh 7f1450 Melaka Tarikh: * Tesis dimaksudkan sebagai tesis bagi ljazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau laporan Projek Sarjana Muda (PSM) ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan den~an menvatakan sekali sebab dan tempoh tesis ini oerlu dikelaskan seba~ai SULIT atau TERHAD. ;)I

3 APPROVAL This thesis submitted to the senate ofutem and has been accepted as partial fulfillment of the requirement for the degree of Bachelor of Manufacturing Engineering (Manufacturing Design). The members of the supervisory committee are as follows: Faculty of Manufacturing Engineering 11

4 DECLARATION I hereby, declare this thesis entitled "A Comparison of Hand Phone Primary Packaging by Using Pugh Method (Case Study)" is the result of my own research except as cited in the references. Signature Author's Name Date :NU : 14th MAY

5 ABSTRACT In the market today, there are various method used by hand phone manufacturer to package their hand phone product. This paperwork contains the report of a comparison of hand phone primary packaging by using Pugh Method. The main purpose of this project is to propose a guideline of hand phone primary packaging. In order to achieve the objective of this project, there are a systematic methodology procedure has been presented in this report. At beginning of the project, the problems, objectives and scopes have been identified to lead the researcher to achieve the target efficiently. The project started by performing a market study. Then questionnaires were distributed to the respondent to make a survey in order to gather information's. The existing product in the market will study on their design of the product and material used based on the survey result. A benchmarking on the six different types of the hand phone packaging box was made. Then a Pugh method concept used to compare the products in order to choose the best product based on the elements that have been studied. The result from the Pugh method was used as a guide to develop a guideline for hand phone primary packaging. The best product will be discussed from their strength elements. From this evaluation, the guideline ofthe hand phone primary packaging was developed. And finally, the conclusion and future work was presented to conclude the study that was done. lv

6 ABSTRAK Dalam pasaran hari ini, terdapat berbagai-bagai cara yang digunakan oleh pengeluar untuk pembungkusan produk telefon bimbit mereka. Kertas kerja ini mengandungi laporan perbandingan teknik pembungkusan telefon bimbit dengan menggunakan kaedah Pugh. Tujuan utama projek ini adalah untuk mencadangkan garis panduan untuk pembungkusan telefon bimbit. Untuk mencapai objektif projek ini, satu langkah sistematik telah dibentangkan didalam laporan ini. Di awal permulaan projek, permasalahan, objektif dan skop telah dikenalpasti terlebih dahulu sebagai panduan kepada penyelidik untuk mencapai target dengan lebih efisien. Projek dimulakan dengan kajian pasaran. Kemudian soal selidik telah diedarkan untuk menjalankan survey bertujuan untuk mendapatkan maklumat. Berdasarkan dari kaji selidik, kajian terperinci dijalankan keatas produk sedia ada dalam pasaran untuk mengenalpasti rekabentuk dan bahan produk. Dari ini, 6 produk penanda berlainan telah dikenalpasti dan kemudian dengan menggunakan teknik Pugh, perbandingan dilakukan untuk mengenalpasti produk terbaik berdasarkan elemen kajian. Keputusan dari perbandingan akan digunakan untuk menyediakan garis panduan untuk pembungkusan utama bagi telefon bimbit. Produk terbaik itu akan dibincangkan berdasarkan elemen kekuatannya. Akhir sekali kesimpulan dan kajian masa hadapan turut dimuatkan di dalam projek ini sebagai penutup kepada kajian yang telah dijalankan. v

7 DEDICATION To my beloved parents; Mat Ghani bin Abd. Rahman Ruhani binti Harun For your love and demonstration the values of education since I'm still a little kid. To my siblings; Hilman bin Mat Ghani Hilmi bin Mat Ghani Nurasma binti Mat Ghani Hisyam bin Mat Ghani For your love, encouragement, and support on this project was absolutely invaluable. To my special person; Shahridzuwal B. Md Jabarulla For your patience whose always tested during writing this project. Your support and understanding are vital part of this research. Vl

8 ACKNOWLEDGEMENT ~ )I ~ )I A..lll F. In the name of Allah, Most Gracious, Most Merciful. All praises to the Almighty Allah, for giving me the strength, patience and guidance throughout the process of completing this research study. I am grateful to have the support and motivation from many people throughout completing this study and I would love to take this opportunity to thank those who are either directly or indirectly involved during the process of this study is conducted. Most immediately, a special gratitude goes to my respective advisor, Miss Suriati Binti Akmal for her precious advice, time, contribution, comments and guidance in every stage of this study. And also my deep appreciation for my second examiner, Mr. Tauftk. My utmost gratitude also goes out to all lecturers from the Faculty of Manufacturing Engineering for being a very nice and effective lecturer to me and thus, making this study easier to be completed. My token of appreciation also goes to my beloved family members who never failed to be there for their love, support and prayers. Last but not least, I would like to thank all my friends, especially my classmates for their never ending supports. May ALLAH bless to all of you. Thank you very much. Nuranisha Mat Ghani UTeMMelaka May 2007 Vll

9 TABLE OF CONTENTS Borang Pengesahan Status Tesis...i Approval...ii Declaration iii Abstract...iv Dedication... vi Acknowledgement.... vii Table of Contents... viii List of Figures... xi List oftable... xiii List of Abbreviations... xiv 1.0 INTRODUCTION... l 1.1 Overview Problem statement Objective of project Scopes of project LITERATURES REVIEW Definition of packaging History of packaging Purpose of packaging Categories of Packaging Packaging Material Plastics Paperboard Vlll

10 2.6 Primary Packaging Box External packaging Internal packaging Bubble wrap Foam Molded pulp tray Plastics Material Characteristic for Electronics Product Guideline for Design for Ease of Packaging Pugh Method Concepts METHODOLOGY Introduction Defme Objective and Scope Literature review Market study Benchmarking Evaluate using Pugh Method Propose Guideline and Improvement MARKET STUDY Introduction Market Study Method Benchmarking of Product Product Product Product Product Product IX

11 4.3.6 Product RESULT AND DISCUSSION Introduction Pugh Method Result Hand Phone Primary Packaging Guideline CONCLUSION AND RECOMMENDATION REJf~RE~C~S APPENDICES A Project Schedule (Gantt Chart) for PSM 1 B Project Schedule (Gantt Chart) for PSM 2 c Hand Phone Packaging Box Survey D E F G H I J Properties of Polyethylene Properties of Polystyrene Folding Carton Price Polyethylene Antistatic Bag Price Ziplock PE Antistatic Bag Price Antistatic Bubble Wrap Price Foam Price X

12 LIST OF FIGURES 2.1 Primary packaging (Sweet dispenser) Secondary packaging (shrink wrapped water bottles) Tertiary packaging Weight of packaging material pie chart Percentage of package goods Single-faced board Single-wall or double-faced board Double-wall board Triple-wall board Folding carton dimensions Types of folding carton Bubble wrap Polyurethane foam a Cell-Aire Foam b Cell-Aire Antistatic Foam c Corro-foam Polystyrene foam Molded pulp tray Plastic packaging material Surface resistivity rate Steps of methodology Transparency plastic view Visi Grip packaging method Polyethylene antistatic bag Folding carton box for Nokia E65 hand phone 34 XI

13 4.5 Bottom layer of foam tray Top layer of foam tray Schematic diagram stacks Ziplock polyethylene antistatic bag Molded foam tray pulp Folding carton box 02 XDA hand phone First folding box Battery charger inside first folding box Second and third folding box Schematic diagram stacks Folding carton box for Treo 700w hand phone Treo 700w packaging method Schematic diagram stacks Plastic tray Antistatic bubble wrap Folding carton box White Helio Drift hand phone White Helio Drift Packaging method Schematic diagram stacks Folding carton box for Newgen n720 hand phone Newgen n720 packaging method Schematic diagram stacks Packaging material Rigid folding carton Schematic drawing of the cushioning material condition Separated compartment for hand phone packaging Wrapped item schematic drawing Antistatic bubble wrap Safe comer for packaging 57 Xll

14 LIST OF TABLES 2.1 Types of plastics Pugh method concept screening matrix Pugh method concept screening matrix Rating reference table Summarization of survey results Properties of Polystyrene Pugh method concept result Strength of products 53 Xlll

15 LIST OF ABBREVIATIONS PE PET pp PVC PS HDPE LDPB RTE STE ESD SD PSM Polyethylene Polyethylene terephthalate Polypropylene Polyvinyl chloride Polystyrene High density polyethylene Low density polyethylene Reverse-Tuck-End Straight-Tuck-End Electrostatics Discharge Static dissipative Projek Srujana Muda XIV

16 CHAPTER ONE INTRODUCTION 1.1 Overview Hand phone can be described as a radio transmitter and receiver. It is designed and manufactured not to exceed the limits for exposure to radio frequency recommended by international guidelines. In this era of globalization, hand phone utilization is very important as a necessity for people to support them in daily communication. Hand phone is a very sensitive electronic product. It is a product of superior design craftsmanship and should be treated with care. Thus, hand phone need a good protection especially in their packaging. Packaging can be defined as a sealed box, bag or container that is used to store or transport the product that requires a protection from tampering. In the market today, most of the current hand phone packaging box design are varies and complicated. In this project, a study will be done on the hand phone primary packaging design. The existing product in the market will study on their design of the product and material used. Then a Pugh method concept will be use to compare the products in order to choose the best product based on the elements that has been studied. The result from the Pugh method will be act as a guide to propose a guideline for hand phone primary packaging. The best product will be discussed from their strength elements. From this evaluation, the guideline of the hand phone primary packaging will be developed. And fmally, the conclusion and future work will be present to conclude the study that was done. 1

17 1.2 Problem Statement In the market today, there are some various method used by packaging department of hand phone manufacturer to package their hand phone. There are no standard or guidelines in producing the hand phone packaging box whether in their design, material and manufacturing process. Because of the various types and complicated method of this packaging box, a study will be done on the hand phone primary packaging design. A study will be done on the existing product in the market based on the important element such as design of the product and material used. A comparison will be done by using a Pugh method concept in order to choose the best packaging box for hand phone thus make it as a guide to propose a guideline. 1.3 Objectives of Project The objectives of this project have been identified and it should be achieved to produce a successful product. The objective is to develop guidelines of hand phone primary packaging. 1.4 Scopes of Project In order to achieve the objective, the scopes are required to assist and set direction of the project development. These scopes should identify and planned appropriately. The scopes are: a) Literature review of the project. b) Study of the current hand phone packaging. c) Evaluation of the product using Pugh method. d) Suggestion of guideline for the project. 2

18 CHAPTER TWO LITERATURE REVIEW 2.1 Definition of Packaging To most people 'packaging' means the carton, sachet, jar etc. which enables a product to be handled and used. It also means the bag or box to carry goods to the home or office. Packaging is the enclosing of a physical object, typically a product that requires protection from tampering. Packaging can be define as a sealed box, cardboard box, bag or container that is used to store or transport good materials. However, to industry and retailers, the term 'packaging' also covers the whole range packaging products used to protect, transport and distribute goods such as corrugated cases, multi-wrap and pallets [I]. 2.2 History of Packaging The history of the packaging was begun over centuries that have undergone an evolution. The very first people to roam the earth have sought to find the way on how to keep the surplus food collecting after they were hunting and fishing. When containers were needed, nature provided gourds, shells and leaves. Later, containers were fashioned from natural materials such as hollowed logs, woven grasses, and even animal organs. Chinese people have invented the cardboard in 1600's but the first commercial cardboard box was produced in England in Corrugated paper appeared in the 1850's [2]. 3

19 At the beginning of the 20th Century goods were delivered in bulk and weighed out by the shopkeeper. This led to unscrupulous suppliers to bulk out products with other cheaper substances or short weigh quantities to make larger profits. In the later half of the century pre-packaging became more common and was welcomed by shopkeepers as it makes the manufacturer rather than the retailer, responsible for quality, quantity and hygiene of the product. It also reduced the time it took to serve customers weighing and wrapping loose goods [2]. Paper and paperboard packaging increased in popularity well into the 20th Century. With the boom in packaging came huge advertising campaigns which sold the products before customers even stepped into the store. The image of the product itselfbecame familiar and was easily recognized on the top shelf or back of the store. Then, the first packaged branded product was launched in 1746 when Dr Robert James sold his 'Fever Powder' in a box. A few years later, Yardley of London began selling its famous lavender water in glass bottles, and Crosse & Blackwell began selling olive oil and mustard in jars. A. F. Pears, also in England, launched what was to become one of the most consistently prosperous industries in the world when he established the first packaged Soap Company [2]. 2.3 Purpose of Packaging Packaging method has such a purpose. This function of packaging can bring a lot of benefit to us either as a product manufacturer, retailer or consumer. First, packaging can be as a physical protection of the products. The product that enclosed in the package can be protected from damage that caused by physical force, rain, heat, sunlight, cold, pressure, airborne contamination and automated handling devices. Secondly, an agglomeration can be done with a packaging. Small objects are typically grouped together in one package for reasons of efficiency. For example, a single box of 1000 pencils requires less physical handling than 1000 single pencils. Alternatively, bulk commodities such as salt can be divided into packages that are a more suitable size for individual households. Thirdly, packaging can give us an information transmission. 4

20 The information on how to use, transport, or dispose of the product is often contained on the package or label. An example is pharmaceutical products, where some types of information are required by governments. Next, packaging is used for marketing purpose. The packaging and labels can be used by marketers to encourage potential buyers to purchase the product. Finally, packaging can reduce theft. It is important to product manufacturer and retailer to save their product from that. So some packages are made larger than they need to be so as to make theft more difficult. An example is software packages that typically contain only a single disc even though they are large enough to contain dozens of discs. 2.4 Categories of Packaging There are three categories of packaging such as primary packaging, secondary packaging and tertiary packaging. Primary packaging is referring to sales packaging. This involves all packaging that is in direct contact with the product. Hence primary packaging could be soft drink bottles or sweet wrappers. Primary packaging can also be described as part of the product. For example if sweets come with a sweet dispenser that pops the sweets into the hand, that sweet dispenser would be known as primary packaging. On the other hand it can be describing products that will be received by customer [3]. The Figure 2.1 shows the example of primary packaging. Figure 2.1: Primary packaging (Sweet dispenser) (Source: _packaging.html) 5

21 While a group packaging is in secondary types of packaging. This is designed to collate primary packaging so that it can be handled manually. Hence a box, containing many soft drinks, or shrink wrap would be secondary packaging. Secondary packaging is used so that goods can be transported more easily, saving energy and costs [3]. The Figure 2.2 shows the example of secondary packaging. Figure 2.2: Secondary packaging (shrink wrapped water bottles) (Source: _packaging.html) The tertiary packaging is referring to transport packaging. It has been designed to prevent damage during the handling and transportation of products. This is used to transport products in large numbers [3]. Hence a crate or pallet containing many small shrink wraps is tertiary packaging. The Figure 2.3 shows the tertiary packaging. Shrink-wrap and pallet ' Figure 2.3: Tertiary packaging (Source: _packaging.html) 6

22 2.5 Packaging Material Material for packaging has a wide variety in the manufacturing world. Generally the selection of material for packaging commonly selected due to manufacturing cost. An essential function of the product package is to protect the product as it makes its hazardous journey from the production line-with transfers and layovers at storage points-to the customer's premises. A package that affords too little protection invariably leads to unacceptably high losses, and one that is overprotective, to high purchase, transportation, and storage costs. Once it leaves its place of origin, the typical product is exposed to multiple hazards: i) damage from shocks and vibrations during normal handling, storage and transportation. ii) deterioration or contamination from foreign matter such as fungi, insects, bacteria, dirt, chemicals, water, and corrosive gases. iii) losses from pilferage or unauthorized package openings. iv) contamination from unanticipated chemical interactions between packaging materials and product ingredients. v) damage from environmental factors such as high temperature, freezing, high-altitude, excessive humidity, and sunlight. vi) creation of surface imperfections such as mars, dents, scratches, finish discoloration, and loss of gloss or shine. The Figure 2.4 shows the weight of packaging material pie chart and Figure 2.5 shows the percentage of package goods. The most common types of material used for packaging such as: i) Plastics ii) Paperboard iii) Bottle or cans (aluminium) iv) Wood v) Glass 7

23 Weight m packaging mlterial % Mixed materials 4% Paper/board 43% Plastics 20% Figure 2.4: Weight of packaging material pie chart Source: INCPEN, Towards greener households, June 2001 ( 1) Mixed materials 5~ Paper/board 25~ Plastics 53~ Figure 2.5: Percentage of package goods Source: INCPEN, Towards greener households, June 2001 ( wasteonline.org. uk/resourcesllnformationsheets/packaging.htm# 1) 8

24 2.5.1 Plastics There are about 50 different groups of plastics, with hundreds of different varieties. All types of plastic are recyclable. To make sorting and thus recycling easier, the American Society of Plastics Industry developed a standard marking code to help consumers identify and sort the main types of plastic. These types and their most common uses are shown as in Table 2.1 [ 4]: Table 2.1: Types of plastics (Source: wasteonl ine.org. uk/resources/informationsheets/plastics.htm) 8~ 8::, "'::, PET HDPE Polyethylene terephthalate (PET) - Fizzy drink bottles and oven-ready meal trays. Protective packaging for electronic goods and toys. High-density polyethylene (HDPE)- Bottles for milk and washing-up liquids. PVC Polyvinyl chloride (PVC)- Food trays, cling film, bottles for L; squash, mineral water and shampoo. LDPE Low density polyethylene (LDPE) - Carrier bags and bin 8::, liners 8::, pp Polypropylene (PP)- Margarine tubs, microwaveable meal trays. PS Polystyrene (PS) - Yoghurt pots, foam meat or fish trays, 8::, hamburger boxes and egg cartons, vending cups, plastic 8::, OTHER cutlery, protective packaging for electronic goods and toys. Any other plastics that do not fall into any of the above categories. - An example is melamine, which is often used in plastic plates and cups. 9