Achieve Target Price and Earn Profits Too!

Whether launching a new product or expanding capabilities to accommodate our clients growing needs, meeting the target price is a significant barrier to earning new revenue streams and potential profits. Sometimes we take on new business opportunities as a way to gain market share, deepen relationships or to gain an advantage over the competition. While these strategies for new business serve their purposes well, it remains essential not only to meet the target price, but also to be profitable at the target price.

Fortunately, approaching target price challenges from both a design improvement and process improvement perspective allows us to open ourselves to a path toward meeting our objectives. A design and process improvement course can make taking risks less emotional and bring us into the realm of rational decision making. What if a design and process improvement method was consistently employed, and the data collected from these efforts demonstrated that a 10%, 15% or even 30% gain in profitability is likely.

One step in achieving a data driven decision-making model is to create processes that deliver reliable data needed to incorporate into an existing decision making and forecasting model. A process that generates and delivers this kind of information is presented below. It is an iterative process that synergizes with a well known Six Sigma concept, Define, Measure, Analyze, Improve, Control (DMAIC).

Step One: Define Base Process

  • Define base process
  • Create value stream map
  • Delineate sub-processes and assign cycle times to each
  • Identify and document opportunities for improvement
  • Present per product price and improvement opportunities

Step Two: Perform Project, Provide performance Feedback and Improvement Opportunities

  • Actual cycle times
  • Yield reporting
  • Constraint analysis
  • Feasibility study
    • Incorporate actual data to engineer design for manufacturability model
    • Material & equipment suitability
    • Yield and process time optimization

Step Three: Adopt New Process

  • Define new process
  • Create new value stream map
  • Delineate sub-processes and assign cycle times to each
  • Identify and document opportunities for improvement
  • Present per product price and improvement opportunities

Step Four: Perform New Process, Provide performance Feedback and Improvement Opportunities

  • Actual cycle times
  • Yield reporting
  • Constraint analysis
  • Feasibility study
    • Incorporate actual data to engineer design for manufacturability model
    • Material & equipment suitability
    • Yield and process time optimization

This iterative process continues to deepen, creating an improvement perspective and can continue until all potential waste is removed, or can be finished when a desired target price and profit is met.  The data gathered from the process can then be integrated into our decision-making models.

While the decision-making model currently in use may not be well structured and documented, we are making decisions and are therefore using some sort of model. Enhancing our awareness regarding how we go about making decisions and adding a rational perspective to our new business strategies can support our efforts to increase revenues and profits.

Click Here to download a case study supporting this model.

Click Here to begin a conversation on how ASAP can help meet your target price initiatives.

Product Packaging: What Is The Impact Of Design For Manufacturability?

DesignWhen designing for manufacturability one of the perceived downfalls is an increase in the cost of materials required for the design.  Consider a master carton.  Various designs of a master carton with similar dimensions, flute, and paperweight specifications have separate manufacturing costs.  One design may require more board and another may require a more complicated die cut. Often design is viewed from a minimization of board and die cutting, leading to a cost only perspective.

However, designing from a cost only perspective can present down-stream manufacturing problems including:

  • Product protection
  • Transportation costs
  • Extra handling

These manufacturing issues can actually increase product costs resulting from product damage, increased transportation costs and increased labor costs.  Imagine if the design required an increase in material cost, but decreased extra handling.

Design Option
Material Cost
Labor Cost
Total Cost
Low Cost Perspective
$4
$12
$16
Design for Manufacturability
$5
$9
$14

On the surface these numbers look inconsequential.  However, this graph below illustrates the saving achieved when designing your packaging for manufacturability.

Designing product packaging is not always easy.  Time horizons continue shrinking as the push for lead-time reduction and quick product launches is ever present in today’s dynamic economy.  However, the opportunity for return on investment makes it clear that manufacturability is a concept that must be incorporated into our design processes.

Picking The Right Carton For Product Packaging

Often in product design, the focus of the design team is on the actual product and its primary packaging.  Although the shipper carton has the important function of making sure the product makes it in perfect condition through the distribution channel, the design of this package can become a rushed afterthought when entering into the launch phase.

Choosing a carton that maximizes your product’s protection without paying extra for an over-specified solution requires that you understand corrugated box construction.  The first place to find out how the carton was designed is to understand the Box Certificate that is printed on most cartons.

 

Bursting Test – This measurement is an indication of the quality of the box.  This number is determined from the Mullen test, which measures the pressure (pounds per square inch) required for the corrugate to rupture.  This measurement is a good indication of how effective the carton will be at maintaining its structural integrity when dropped or loaded with heavy contents that exert pressure on a small area of the carton.  Certification with this test requires the corrugate to be constructed within specific parameters.

Edge Crush Test – This is a new standard that is sometimes used in place of the Bursting Test.  This measurement indicates the stacking strength of the carton by measuring the minimum pounds per linear inch needed to compress the edge of the corrugate board. This method of measurement allows manufacturers to use less expensive, lighter weight board than what is required for a Burst Test certified carton.

Minimum Combined Weight On Facings – This measurement is an indication of the stacking strength of the carton certified with the Burst Test.  This number is the weight the sides of the carton can hold up when a load is applied to the top.  This measurement is generally indicated in pounds per square foot.

Size Limit – This number indicates the maximum carton size allowed for the corrugate board used to construct the box.  This is determined my adding the length, width and height of the carton.

Gross Weight Limit – This value indicates the maximum weight that can be loaded into the carton.  Although this is the specified maximum weight, consideration should be given to the type of product loaded into the box and the mode of transportation to determine what weight should actually be loaded into the carton.  A carton loaded to the weight limit with an irregularly shaped item may not be adequately protected.  Also, a carton at the weight limit may be adequately protected when palletized but prove inadequate when shipped as an individual parcel.

The goal of protective packaging is to get your product through the distribution channel and into the end user’s hands in pristine condition. Understanding the Box Certificate is a great starting point to knowing if your carton will be adequate to achieve this goal, and put you on your way to achieving your larger goal of bringing your product successfully to market.

Box Maker’s Certificate
All About Boxes
Technical Notes On The Use Of Corrugated Paperboard Boxes
Box Manufacturer’s Certificates
Understanding the Box Maker’s Certificate

 

Creating New Product Launch Teams and Partnerships

New product launches require great commitment, coordination and communication among and across a diverse cross section of specialized skills.  Developing teams and partnerships to navigate the complexities inherent in new product launches becomes increasingly important as demand for speed to market increases while resources to facilitate speed decrease.

There are several factors to consider when building collaborative relationships leading to high performing product launch teams.  Some of these characteristics include:

• Trust:  Working with people you can trust creates an open environment where honest dialog regarding product and market needs are expressed.  Communicating in this manner is efficient and facilitates planning, problem solving and systems development.

• Experience:  People experienced in new product launches understand the complexities inherent in new product launches, enabling an anticipatory perspective.  Often, experience and learning from the last launch is incorporated into the next launch avoiding problematic constraints.

• Expertise:  Specific knowledge in areas such as the product, markets, channels, engineering, manufacturing and organizational systems are great resources to have on your team.  Understanding the strengths and weaknesses of specific technical areas is helpful in over coming problems by leveraging strengths and engaging other options where needed.

• Flexibility:  New product launches are dynamic and evolve as new information is learned, presented and incorporated into launch plans.  People who understand the iterative process can remain open-minded and malleable with out being attached to any one plan or one way to approach a problem.  Remaining agile in a new product launch helps keep the launch moving forward in a dynamic environment.

New product launches are demanding. Beginner, practitioner or expert, it is easy to feel engulfed by an impending new product launch. Having great teams and partnerships working in unison makes all the difference.

 

Integrating Brand Strategy Into Product Packaging

We understand the importance packaging plays in purchasing decisions. Often the quality of the package is only one of the determining factors in the complex purchasing decision-making process. Perhaps the most important factor, however, is how well brand strategy is communicated and integrated at the point of purchase.

While it may seem difficult to incorporate the intangible aspects of brand strategy into product packaging, the first step in the process is obtaining a thorough understanding of the target market. Like all great, simple solutions, there is more to the story than age, race and gender. We need more information to create a connection with our buyers.

Here are a couple points to consider when integrating brand concepts and strategies into product packaging:

Functionality ~ does the packaging promote the product’s use?

Understanding how the target market uses the product is key. Learning how well the package facilitates the use of the product is helpful in identifying opportunities for improvement and product differentiation. A good example is Duracell’s repackaging efforts for its hearing aid batteries. Knowing their target market struggled to open the package, remove the battery and place it into the hearing aid, the company designed packaging to help their buyers use their product. They made it easy to change hearing aid batteries. Integrating functionality into the package redesign brought increased sales leading to brand loyalty.

Typically, products/brands are created to solve a problem within the market place, integrating functionality into product packaging as part of the solution helps communicate brand strategy.

Personality ~ does the packaging reflect the characteristics of both the brand and persons targeted to purchase?

Understanding the traits, behaviors and emotional characteristics of the target market is another important factor in integrating brand into packaging. Knowing what images, colors, textures and shapes appeal to the market is helpful in creating a connection with consumers. Presenting a consistent message between the product and package helps build confidence and trust in brand personality. A good example of this is when ATK, a company that makes bullets, launched a new bullet for duck hunters. The company integrated images and bright colors, into its package design, reflecting personality attributes of its target market. Integrating personality into packaging helped make this a new product launch a success.

Functionality and personality are important factors to consider when integrating brand strategies into product packaging. The benefits of learning more about target markets, and combining this information into product packaging are compelling. Increased sales, brand awareness, brand loyalty, and increases repeat sales all sound great!

Certainly, there are more criteria to consider than just functionality and personality. To learn more about the products discussed and additional criteria and methods, please see the resources listed below.

Duracell EasyTab
ATK Article
Design Matters // Packaging Book

Great Product Packaging

We know it when we see it.  It triggers a curious feeling, an impulse to pick it up, to touch it, and to bring it home with us.  No, it is not a puppy!  It is a great product -packaged with great care – in great packaging materials.  Often, in the buyer’s eyes, the package the product is in, is synonymous with the product. People associate the quality of the product and the experience using the product with the packaging (marketing) the product is in. With packaging playing such an important factor in a product’s image and ultimately sales, here are five elements of packaging that helps to create a connection with the buyer.

Materials
Material choice is an important factor in package quality. Material quality ought to reflect the value of the product being sold.  Material choice may include the gauge of shrink wrap; paper weight of a retail box, the mil thickness of a poly bag  or the flute size best suited for graphics reproduction and stacking strength.  Materials selected needs to endure the distribution channel and the retail environment while accurately reflecting brand attributes.

Product Protection Systems
Packaging needs to protect the product from elements within its manufacturing environment and distribution channel.  A product that is well protected may have many layers in its packaging system, such as a primary package that is sealed, a secondary package to reduce movement and a tertiary package.  A retail package’s tertiary packaging may be the retail box placed on the shelf for purchase. An OEM package’s tertiary packaging may be the distribution box that is stored at the distribution location.  Finally, how the product is unitized, its pallet pattern and pallet protection all contribute to how well the product is protected.

For More Information

Check out this video to learn more
about how to prevent product damage within the supply chain.

Click Here to learn more about how
ASAP can help you with your
damaged product issues.

Processes
Packaging processes need to be complimentary to the product’s manufacturing processes, sequenced correctly and given as much attention as the creation of the product itself.  Packaging processes requiring employees to double and triple handle product are inefficient.  Inefficient process can lead to quality problems, such as missing components.

Ease of use
Ease of use factors for the end user include the ease of opening the package, the layout of the product and its accessories and handling for distributors.

Branding
From a brand prospective, packaging needs to communicate both emotional and rational information about the product.  Colors, font choice, images and logo placement on the package creates an emotional response to the product. Text and other content inform the user of product features and benefits.

As consumers, buyers and end users, we have difficulty differentiating the product from its package.  We tend to believe the image communicated in the packaging is the product we are buying.  With this knowledge, It is important to develop great packaging to promote and protect our great products, make connections with our target market, increase sales and help consumers feel good about their purchase decisions.


What You Should Know About the Basics of Prototyping

By David Clark, New Business Development Manager, the Malco Design & Deliver Group

When it comes to designing and preparing a prototype, the first questions we ask is, “What is the goal of the prototype?” The answer is not as obvious as you might think.

 

The design and production of prototypes in the product development process creates compelling opportunities for patenting, licensing, investor relations, market research, product refinement and ease of manufacturing. Deploying the right prototype at the right time for these uses saves time, saves money and enhances the end-user experience while increasing the chance of a successful new product launch.

In the product development life cycle, three basic varieties of prototypes build on one-another to reach the point of manufacturing. Increasing in sophistication and capital investment, these prototypes can be thought of as three distinct design processes.

  1. Conceptual Drawing and Virtual Prototypes
  2. Working Models
  3. Pre-Production Samples

Conceptual drawings and virtual prototypes are the most cost effective prototypes in the design process. Conceptual drawings and virtual prototypes are used the early stages of market research and to gather customer feedback. Additionally, they are used to gauge investor interest and for selling or licensing a patent.

Once market interest is solidified and investors commit, the working model prototype further refines the product to demonstrate the proof of concept, size, fit and functionality. Working model prototypes provide investors and the target market a hands-on working model for feedback and critique to further the design process.

Often confused, a working model prototype differs significantly from a mock-up. Mock-ups, while useful, are made in the earliest stage of product development using convenient materials at hand. Working models are prototypes made of materials that closely resemble and are consistent with design specifications. Working model prototyping creates a product ready for real life testing.

 

The pre-production sample is the most costly prototype to make. Therefore, it is produced only when the majority of design decisions have been made. Using the information gathered in the previous stages, the final stage of prototyping uses the pre-production sample to study and enhance the Design for Manufacturability (DFM) of the product. For more information read:Benefits of Design for Manufacturability.

____

David Clark holds a BS degree from Minnesota State University, Mankato and an MBA from the University of St. Thomas. He has over 20 years of sales, marketing and product development experience. Dave has worked for Malco Products, Inc. for eight years.

 

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