Improving secondary packaging properties with transport simulation in a firm producing fast moving consumer goods

This thesis includes work on improving the secondary packaging features of liquid detergent bottles in a fast-moving consumer goods (FMGC) factory. The production process involves filling liquid detergents into bottles, securing them with caps, and placing them in corrugated cardboard boxes. These boxes are stacked on pallets and transported by trucks on the road. The study involves modeling of the liquid detergent bottles, caps, and corrugated cardboard boxes. Transport simulation is conducted by adding potential vibration data that the corrugated cardboard boxes may experience during transportation. During the model setup phase, Top Load tests are conducted on actual products to validate its accuracy. Based on the simulation outputs, recommendations are made for cost reduction improvements concerning the corrugated cardboard boxes. Subsequently, physically improved samples of corrugated cardboard boxes are obtained and subjected to physical transportation testing, implementing the suggested improvements. A comparison is made between the physical transportation test results using the improved corrugated cardboard boxes and the new simulation model established with the enhanced boxes. The cost advantage that can be achieved annually when implementing the improvement suggestions is calculated.