Trust, But Validate All Product Packaging Components

December 28, 2010 by Leave a comment

Validating all product packaging material is a critical step to ensure our product launches occur on time and within budget. Imagine, successfully navigating a very long and rigorous new product launch process only to discover, the launch is delayed by several weeks simply because the packaging material, such as a master carton, was not validated.

Something as seemingly simple as the correct sized master carton can have a major impact on meeting launch dates and anticipated profit margins. For example, a carton purchased that is too small for the product leaves us with a few options.

  1. Find an online resource that specializes in, in stock, off the shelf cartons and purchase the closest match to the dimensions and weight restrictions of the product. If necessary buy a larger box than required and fill the void with packing paper, print and apply carton labels, getting the product to market a few days later than planned.
  2. Change the carton drawing with the corrugate supplier, augment the printing and cutting die, and wait another 2 weeks to receive cartons, launching the product at least 2 weeks later than planned.

The first option gets the product to market sooner, but has several extra costs involved, affecting targeted profit margins. The second option can delay the launch by 2 to 4 weeks, depending on supplier lead times and our own product processing times and manufacturing schedules.

With both options, there are extra costs involved, including:

  • the extra cost per carton
  • the cost to return, destroy or inventory the wrong sized carton
  • the cost to augment or produce a new cutting and printing die
  • the cost to order the correct carton
  • the cost to print and apply a carton label
  • the cost to purchase and insert packing paper

To avoid these and other more, intangible costs validate all product packaging material before purchasing and launching new products.

 

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What You Should Know About the Basics of Prototyping

July 28, 2010 by Leave a comment

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.

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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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