BRIEFING The first step is to clarify the goals what the customer wants what limitations apply and how the packaging is to be used This analysis is supplemented with detailed discussions with the parties involved and close inspection of the product For these bicycles the briefing was comprised of a video that showed the previous packaging Numerous separate parts were to be simplified to a single shape to reduce the cost and facilitate production Any one size fits all approach was made difficult by various tyre sizes A clever solution was called for PLANNING Initial ideas were prototyped virtually using state of the art computer technology The most promising approach seemed to be to dimension the cover and holes to accommodate tyres of maximum thickness Pre cut inserts were to make the basic shape suitable for any tyre and model But would a modular approach be sufficiently safe and sturdy OPTIMISATION To firmly fix all of the elements the developers designed a system of flaps to connect the cover with the box on the outside Our developers did computer testing to ensure that all the provisions and requirements for logistics and production were fulfilled TRYOUT In this step the first real corrugated cardboard sample was created which is always an exciting moment for the developers It s the first opportunity to find out whether the design is really able to weather any eventuality All tests in the laboratory went off without a hitch so then it was time for the biggest step of all EXECUTION No matter how perfectly developers understand their customers and their needs there s no way around a final field test under real world conditions with the actual product For the first time the bicycles were packaged in the prototype and then shipped to examine the handling and safety characteristics In the worst case it would be back to the digital drawing board But the packaging passed the test with flying colours IMPLEMENTATION Depending on the scope of the tests it may be necessary to produce small batches to play through every possible use case Once the design has received green light the product is ready for series production Kunert Wellpappe has a new product In case of the bicycle packaging it s now ready for sale The developers are glad to have used their skill to satisfy another customer

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