I'm modelling an FR10 pallet layout with cartons that have two reinforced base strips. Rotate the upper layer and several strips bridge the finger gaps below; the nice solid boxes in our model hide all of this.
Add sections through the filled cartons and both layers. Packaging needs to see where the load actually bears, and tooling needs the release and withdrawal space on the same layout.
Then get the movement after placement. A gap that accepts the fingers isn't automatically a gap they can leave through once another carton is beside them.
Keep the packing contents in that review too. We have had two cartons with the same outer dimensions and different internal support, so the outline alone was a very persuasive distraction.
I've added the packed section. Packaging is proposing a non-alternating pattern; dispatch dislikes the lower count, tooling hasn't checked the exit route yet.
Could a layer sheet be another candidate, if packaging thinks it can provide the needed support? Not saying put any old sheet in there and declare victory.
Worth asking, but include placing the sheet and handling its supply in the comparison. Otherwise dispatch gets its carton count back by handing an unpriced task to somebody else.
Packaging will assess a specified sheet as a second option. We're keeping the lower-count pattern in the comparison rather than treating the sheet as an agreed fix
Tooling has found a withdrawal clash in the original pattern. They've proposed a finger change, now going back to packaging with the revised gaps. Neither option has a filled-load trial result yet.
Has dispatch priced the lower-count option now? It may still be less work than revised fingers plus a sheet supply, even if it loses the beauty contest on the drawing.