Clip-Lok in Spain was met with a unique challenge when contacted by Airbus to discuss packaging for wing ribs for their Airbus A380.
The job involved designing a reusable packaging solution which could safely transport sets of wing components from Spain directly to the production line in England. The boxes would be used for four different wing models. Each model required five unique boxes which could each hold a series of eight ribs. So all in all there was a need for twenty different boxes, each with specially designed dunnage.
The ribs would need to be packed by the manufacturer in a specific order and be easily accessible so the boxes could function on the Lean production line in England. Once on the production line, the workers needed easy and sequential access to the parts directly from the box without any unnecessary handling.
In addition, a metal structure would have to be integrated into the bottom of each box to allow the boxes to be moved via special tracks within the factory.
Pablo Losa, Sales Manager at Clip-Lok SimPak Iberica, explains how the challenge was met, “We worked closely together with Airbus Spain and Airbus’ technical support partner, IDEC, to secure information about the components and the specific transport and handling requirements. The boxes and dunnage were then designed using CATIA 3D design software.” Pablo Losa continued, “Using the computer-generated drawings of each wing component, we designed a solution where each rib is cradled in the correct order on specially designed protective racks. This solution provides excellent support and protection and optimizes space within each box.” Upon arrival to the production line, the lid and front of the boxes can be opened within seconds giving the workers easy and sequential access to the parts.
As a result of perseverance, cooperation and attention to detail, Airbus is very pleased with the boxes which are now a vital part of their production process.