5.3.3 How to generate unit-load pallets as much as possible

When the goods are palletized first and then loaded into the container, it is required to generate unit-load pallets as much as possible. How to define such requirement in LoadMaster?

Cargo data:

name	quantity	length（cm）	width（cm）	height（cm）
A	257	50	40	20
B	133	60	50	25
C	180	60	50	24
D	367	30	32	26
E	49	60	80	20

Loading requirements:

1) The goods can only be placed as the height is vertical to the ground.

2) Calculate how the goods are palletized and then loaded into a 40GP.

3) When the goods are palletized, unitload pallets are generated first, and then the mixed pallets.

4) There are two types of pallets: 1200*1000mm, 1200*800mm. The pallet height is 10cm, and the max load height is 1.2m (including the height of the pallet itself).

According to the current loading requirements, the task type [2-Steps Loading] should be selected.

Enter the [Basic Information] interface. The items in this page is optional, and users can fill in the PO number, order number or destination information according to actual work requirements for later check. Next, start to designing the plan:

Step 1: Click [Cargo] on the left to enter the cargo interface. For there are lots of cargo types, you should add them in batches by [Add Cargo>Import From Excel]. Firstly, click [Add Cargo>Get Excel Template] to download the Excel template and save it to a certain location in your computer.

Secondly, fill in the template with the cargo information. ①Copy the name, quantity, length, width, height, and weight (gross weight of a single box) of the goods into the template, which are required items. Pay attention to the matching of the units. “Weight” refers to the gross weight of a single carton or box of goods. If the cargo is too light, the “Weight” can be ignored and not filled in, and the system will default to "1".

②Then define the load orientations of the goods. For it is required that cargoes can only be placed as the height is vertical to the ground, that is only “stand” and “stand & rotate” are allowed, you should fill in “0” under the “allowed” Column of other orientations. “0” means not allowed such load orientation, leave it blank or “1” means allowed.

③Define the properties for loading. For the goods are required to be palletized and then loaded into the container, the "Intermediate Packing Method" of the goods is set to "1". “0” or blank means that the goods are directly loaded into the container; “1” means that the goods are free to choose the appropriate pallet/carton; “2” means that the goods are loaded with the designated intermediate packaging.

For there are no other requirements, you do not need to set other parameters, leaving them as the default value. The specific details of each parameter can be found in this guidance documentation. Save and close the template when finishing. Thirdly, return the [Cargo] page, click [Add Cargo>Import From Excel], choose the template in the dialog box, and open it. Then the cargo information will be imported to the task.

Step 2: Click the [Container] on the left to add a container. For this batch of goods will be loaded with 40GP, you only need to add 40GP into the task. (If you don’t know what type of container to use, you can check the commonly used container type to add them in so as to the system can automatically select containers). Click [Import from Database], check 40GP in the pop-up box, and click [Add]. Set the corner castings and reserved size of the container. Precautions for defining the reserved size, please refer to "How to simulate carton expansion and manual interval".

Note: For this case is pallet loading, the height reserved size should be set to 10cm in order to facilitate forklift operations; therefore, the 10cm of container corner castings are also deducted, therefore the size of corner castings does not need to be set.

Step 3: Click [Intermediate Container] on the left to add a pallet. Common used pallet information has been stored in the database. But the pallet used in this case is not in the database, you need to add them one by one. Click the [flat pallet] under [Add Container], and then edit the name (for example, “pallet 1200*1000”). The size of the pallet is 120*100*10cm, and the "maximum load height" is 120cm. In the same way, add the second pallet 1200*800.

Note: In order to avoid repeated input each time, you can also maintain the commonly used pallet in the database. Check the two pallets, and then click [Save selected containers in database]. Next time you can use these two pallets by [Import from Database].

You can also maintain the commonly used pallet in the database before designing loading plan. For details, please refer to the above "Container Management" .

Step 4: Click [Loading Rules] on the left to enter the [Loading Rules] page. For there is no special loading demands, you needn't change the default rules in this page.

Step 5: Click [Intermediate Loading Rules] on the left to define the loading rules when the goods are palletized. For it is required to give priority to the generation of unitload , you need to check [Prefer unit load], and set [Minimum volume usage rate required for unit load].

Finally, click [Optimize] above or click [Loading Plan] on the left to calculate. In the middle is the 3D loading effect diagram. On the right side of the diagram are cargo statistics, loading steps and balance analysis of the current container. According to the 3D diagram, you can see that the goods are first generated unit load, and then few mix load, which fully meets the loading requirements. If there are more mixed pallets, you can back to the [Intermediate Loading Rules] interface, and adjust the [Minimum volume usage rate required for unit load] to be appropriately lower.

After the scheme audit is completed, you can use your mobile phone to guide the on-site loading and download the loading report to make the packing list and customs declaration. Details please refer to this guidance book.