Auxiliary packaging

Auxiliary packaging refers to materials such as lids, foil, lining, or trays used as supportive packaging for generated handling unit structures. In LN, packaging materials are referred to as auxiliary packaging items.

Similar to packaging items, auxiliary packaging items are defined as packaging items in the Packaging Items (whwmd4505m000) session. Auxiliary packaging items are specified in the Auxiliary Packaging Item field of the Handling Unit Template Node - Auxiliary Packaging (whwmd4162m000) session.

For each handling unit template node, you can define different auxiliary packaging items. You must specify the method to calculate the required quantity for each auxiliary packaging item. The quantity of auxiliary packaging items can be calculated based on the number of:

Items contained in the entire generated handling unit structure
Packaging items of the child handling unit
Packaging items of the current node

The quantity of auxiliary packaging items is calculated using the values of these fields in the Handling Unit Template Node - Auxiliary Packaging (whwmd4162m000) session:

Note

The offset quantity is the part of the based-on quantity that is excluded from the calculation.

The formula used to calculate the required quantity of auxiliary packaging items:

(<quantity used> - Offset Quantity) / Based on Quantity) * Auxiliary Packaging Item Quantity

The <quantity used> value is determined by the option specified in the Based On field. This can be the Packaging Item, Child Packaging Item, or Content quantity.

Example 1

A full pallet carries 40 items, stacked in five layers of 8 items each, and one tray between every two layers. Also, the top layer is covered with a lid. A full pallet requires one lid and four trays. The bottom layer does not require a tray, because it is stacked directly on the pallet.

Incomplete pallets require one lid, but fewer trays. The required number of trays depends on the quantity of items packed in the generated handling unit structure.

This is modeled by defining a variable package definition and a handling unit template consisting of one node. For this node, the main packaging item is PALLET, and the item quantity is 40. The lid is defined as auxiliary packaging item LID, and the trays are defined as auxiliary packaging item TRAY. The calculation of the required quantity of auxiliary packaging items is based on:

Auxiliary Packaging Item	Auxiliary Packaging Item Quantity	Based On	Based on Quantity	Offset Quantity	Only Apply when Full
LID	1	Packaging item	1	0	Cleared
TRAY	1	Content	8	8	Cleared

Regardless of the number of stacked items, a pallet requires one lid. Therefore, 1 auxiliary packaging item LID is based on 1 main packaging item PALLET:

([1 PALLET - 0 offset quantity] / 1 based on quantity) * 1 auxiliary packaging item quantity = 1

The required number of trays depends on the number of items stacked on the pallet. Therefore, the calculation of the number of trays is based on the handling unit content. Each layer of 8 items requires one tray. So 1 TRAY is based on 8 items. However, the bottom layer does not require a tray. Therefore, 8 items are left out of the calculation. The quantity left out of the calculation is specified in the Offset Quantity field.

For a full pallet, the calculation of the required quantity of auxiliary packaging item TRAY is:

([40 items - 8 items offset quantity] / 8 items based-on quantity) * 1 auxiliary packaging item quantity = 4

If only 24 items are stacked on the pallet, the calculation is:

([24 items - 8 items offset quantity] / 8 items based-on quantity) * 1 auxiliary packaging item quantity = 2

For 18 items:

([18 items - 8 items offset quantity] / 8 items based-on quantity) * 1 auxiliary packaging item quantity = 1.25

The quantity of 1.25 is rounded up to 2, because the Only Apply when Full check box is cleared. This means, that a tray is also specified for layers with fewer than 8 items.

Note

In this example, it is not allowed to set the Based On field to Child Packaging Item because the handling unit template has only one node.

Example 2

Handling unit template
Node	Main Packaging Item	Packaging Item Quantity	Item Quantity in Storage Unit
1	PALLET	1
2	CRATE	2
3	BOX	12	120

1 main packaging item PALLET has 1 COVER as auxiliary packaging item.

Each CRATE contains 4 FOIL as auxiliary packaging items.

A BOX contains 10 items. A full pallet contains 120 items packed in 12 BOXES.

If 3 BOXES are available in a CRATE, 1 TRAY must be added as auxiliary packaging item. For a full CRATE, 2 TRAYS are required. The TRAY is only added if there are 3 BOXES, therefore, the Only Apply when Full check box must be selected.

The following auxiliary packaging item quantities are defined:

Node	Auxiliary Packaging Item	Auxiliary Packaging Item Quantity	Based On	Based on Quantity	Only Apply when Full
1	COVER	1	Packaging item	1	Cleared
2	FOIL	4	Packaging item	1	Cleared
2	TRAY	1	Child packaging item	3	Selected

A pallet requires one cover, regardless of the number of stacked crates or the number of boxes contained in the crates. Therefore, 1 auxiliary packaging item COVER is based on 1 main packaging item PALLET:

([1 PALLET - 0 offset quantity] / 1 based on quantity) * 1 auxiliary packaging item quantity = 1

If the handling unit structure is generated for 120 items, two CRATES are generated for node 2. Each CRATE requires a fixed number of 4 FOIL, regardless of the crate's contents. Therefore, 4 FOIL are based on 1 CRATE, and there is no offset quantity.

For the CRATES, the calculation for the required number of FOILS is:

([2 CRATES - 0 offset quantity] / 1 based on quantity) * 4 auxiliary packaging item FOIL = 8

The required number of TRAYS depends on the number of BOXES generated for node 3. The total number of BOXES generated for this node is 12 (6 BOXES in each CRATE). One TRAY is required for every 3 BOXES. Therefore, 1 TRAY is based on 3 child packaging items BOX. Because a full CRATE contains 6 BOXES, each CRATE requires 2 TRAYS. The total number of TRAYS is 4, 2 for each CRATE.

The required number of TRAYS is calculated individually for each CRATE. The results are then added up for each CRATE:

CRATE 1) = ([6 child packaging item BOX - 0 offset quantity] / 3 based on quantity) 
* 1 auxiliary packaging item quantity = 2

CRATE 2) = ([6 child packaging item BOX - 0 offset quantity] / 3 based on quantity) 
* 1 auxiliary packaging item quantity = 2

If the handling unit structure is generated for 72 items, two CRATES are generated for node 2. The calculation of the required number of FOIL is identical to the calculation applied to a full PALLET, even though the second CRATE contains only 2 BOXES.

The required number of TRAYS:

CRATE 1) = ([6 child packaging item BOX - 0 offset quantity] / 3 based on quantity) 
* 1 auxiliary packaging item quantity = 2

CRATE 2) = ([2 child packaging item BOX - 0 offset quantity] / 3 based on quantity) 
* 1 auxiliary packaging item quantity  = 0.66 = 0

The quantity of 0.66 is rounded down to 0, because the Only Apply when Full check box is selected. This check box is selected because a TRAY is only required for a minimum of 3 BOXES.