Dealing with Packaging Complexity: Tips 13 to 16
By Stephen McIndoe, VP Consulting, Be4ward
In my previous articles (see end of article for list), I discussed a series of tips on managing packaging complexity. In this article, I will examine the next four tips, which continue on the theme of how to cope with added-value complexity.
13. Postponement
Can you postpone customization to as late as possible in the supply chain?
There are a number of definitions of postponement, but the one we will use here is the delaying of customization of a product until as late as possible in the packaging operation.
There are many examples of this:
- Filing blank bottles or cans for stock and labeling when fulfilling a specific order
- BIB/BOB (blisters in boxes, blisters out of boxes) e.g. producing standard blisters for stock and packing into cartons at a later stage to create market specific packs
- Assembling different combinations of standard components to create a unique pack variant for a specific market
In all cases, it can be seen that the goal is to keep the product as standard as possible for as far through the packaging operation as possible and then only make it market specific at the latest possible operation, perhaps against a specific market order. This can present a number of challenges for most operations:
- Additional quality system control to manage intermediate handling and subsequent further packaging operations
- With fill and pack lines, it can be necessary to remove the product partway through the operation and then run it down the line again at a later time to complete the packaging
- Hand packing can be required for the final assembly of small batches
- The design and characteristics of some products and components make it very difficult to avoid making them market-specific until late in the process
14. Late Customization
Can you "late customize" components and products?
Our definition of late customization is the physical modification of standard components and products to add features or information, making them product or market specific. Examples would include online printing of content and over-labelling and may be taken downstream of the packaging facility.
Online component printing is becoming increasingly common, but it depends upon the type of component and information required:
- Online printing of foils and labels is often undertaken, particularly if only requiring black ink
- Equipment for near-line short-order printing of leaflets and booklets is becoming available
- Online printing of multi-color cartons (particularly pre-glued) is more complex with fewer examples, although digital presses are increasingly used at print suppliers for short runs
Over-labeling can vary between simple printed labels (pharmacy labels) to complex labels (e.g. including sealed pouches for leaflets).
A few considerations with late-customization and over-labeling:
- How do you assure the quality of print for all components? A missing decimal point could have significant consequences.
- How do you ensure the line speeds are not significantly impacted? Is near-line printing a better option?
- Do online printing machines require different artwork files or formats? Where are these files stored and how does that impact your artwork process and system uptime?
- Can your MRP system provide the necessary breakdown of SKUs and components?
15. Packaging Design
Have you designed your packaging to maximize the opportunities to deal with complexity?
All of the different techniques we have discussed in these tips offer opportunities for dealing with low volume products and managing complexity, but they may not be feasible with your existing packaging designs. It may therefore be necessary to revisit some of the structural or artwork elements of the design to exploit specific techniques. These can include:
- Changing component artwork to make it standard across multiple countries (or even removing all market specific information)
- Grouping all market specific information on certain areas of the artwork (like the EU blue box concept)
- Providing space on components and artwork for online printing requirements or application of labels
- Reducing colors to make on-line printing easier
- Changing component size to provide more printing space
- Providing pockets or flaps on cartons for attaching leaflets and booklets
- Standardizing sizes, platforms, layouts and templates
- Using color coding, poke-yoke and pharma codes or data matrix codes to aid control of assembly operations
It is therefore important to ensure that a holistic approach to packaging design is taken, ensuring effective design for manufacture.
16. Build Flexibility Into Packaging Equipment
Do you have the right type of packaging equipment that provides suitable levels of flexibility?
It is often tempting when specifying equipment to specify the fastest packaging lines. Indeed, due to being pressured for ever increasing levels of efficiency, most packaging operations would love to be producing high volumes of few variants as fast as possible.
However, as we have discussed, the healthcare marketplace is increasingly not like that, as volumes are decreasing and complexity is increasing. It is therefore important when specifying packaging equipment to ensure that the correct criteria for how the portfolio needs to be supplied are defined and agreed.
Trends are driving this to much more flexible machinery that can be easily changed for different pack formats, with the ability to insert specific modules when required (e.g. serialization printing modules) or the ability to split fill and pack lines to permit part packing.
Due to the capital costs required, it is unlikely to be feasible to re-equip packaging facilities at a later date. Therefore, making the right choice of equipment to support your expected portfolio and supply strategies is a critical strategic decision.
My next article will look at the final four tips to cope with added-value complexity.
Other articles in this series:
Dealing With Packaging Complexity
Dealing With Packaging Complexity: Tips 1 To 4
Dealing With Packaging Complexity: Tips 5 to 8