How is the cell count of a Small Plastic Case set for kitting?

Count size bands, not parts. One band shares one cell, width lands between 48 and 65 mm, and a 150 by 100 mm cavity gives six, nine or twelve cells.

Why build a spare kit by family rather than by part?

By part a kit passes 20 units, the carton goes overweight and the handle fails first. By family it stays at 5 to 8 cases under 3.2 kg.

What slot gap holds a Small Plastic Case in a host case?

2 mm, 1 mm per side. Under 1 mm shrinkage blocks seating; over 4 mm a drop walks it 6 mm into the panel.

Why not use a clear pouch for the label?

A 0.15 mm pouch stands 0.6 mm proud, takes a crease from the case above and splits by the third card.

Do friction ribs really stop sliding?

At 0.5 g they cut slip from 12 to 2 mm. Once they wear to 0.3 mm the effect is gone.

Small Plastic Case Uses: Parts, Spares and Accessories

Quick answer: A Small Plastic Case lands in three places: line-side kitting, spare kits and host-machine packing. Cell count and cell width decide kitting, at 800 g per cell. A spare kit runs 5 to 8 cases of one shell at 152 by 102 by 52 mm. Accessories ride on four ears with a 2 mm slot gap.

How a Small Plastic Case Divides Cells
How Many Cases a Spare Kit Needs
Fixing Accessories in the Host Case
Service Carts and Line-Side Shelves
Label and Identification Faces
FAQ

1. How a Small Plastic Case Divides Cells

Kitting starts by counting cells. A Small Plastic Case takes its cell count from the size band of the parts, and cell width follows from that count.

One 150 by 100 mm cavity leaves 148 by 98 mm after a 2 mm divider: six cells at 65 mm, nine at 55, twelve at 48. Under 48 mm a gloved finger cannot reach in, and 800 g per cell caps a twelve-cell case at 9.6 kg.

Cells	Layout	Cell width	Per cell	Cost of missing it
6	Two rows of three	65 mm	800 g	Above 70 mm parts roll over
9	Three rows of three	55 mm	800 g	0.5 mm drift misaligns dividers
12	Three rows of four	48 mm	800 g	Under 48 mm fingers cannot reach

2. How Many Cases a Spare Kit Needs

Case count follows part families, not part count. A machine has 5 to 8 wear families, so a kit carries that many cases on one shell of 152 by 102 by 52 mm.

Six pack into a 320 by 220 by 110 mm carton with 4 mm of cushion. A kit is capped at 3.2 kg, past which the carton handle sees 60 N. A 15 mm seal strip sits 10 mm clear of the label window.

Kit	Cases	Carton	Kit weight
Small	5	320×220×110 mm	2.4 kg
Standard	6	320×220×110 mm	3.2 kg
Extended	8	430×220×110 mm	4.1 kg

3. Fixing Accessories in the Host Case

An accessory Small Plastic Case shipped in a host case is judged on staying put, not capacity. Four ears, 6 mm tall, hold a slot 2 mm wider than the shell, leaving 1 mm per side.

Under 1 mm, 0.55 percent shrinkage blocks seating; over 4 mm, a 1.2 m drop walks the case 6 mm into the machine panel. Ten millimetres of air keeps the hot face from softening a PP wall at 70 C.

Point	Size	Gap	Failure mode
Ear height	6 mm	slot depth 6 mm	Shallow ear lets the case hop out
Slot width	shell plus 2 mm	1 mm per side	Tight jams, loose hits the panel
Air gap	10 mm	not under 8 mm	Flat contact softens the wall
Ear root	1.4 mm	R0.8	Thicker root cracks the shell

4. Service Carts and Line-Side Shelves

Drawer clearance sets the height of a Small Plastic Case: a 60 mm drawer takes a 52 mm case and leaves 8 mm for a finger, while 58 mm lets the drawer press a white mark into the edge.

Four 0.8 mm friction ribs hold slip to 2 mm at 0.5 g. Shelf pitch runs 180 mm, where six 152 mm cases fill 912 mm of a 900 mm shelf.

5. Label and Identification Faces

The label window sits 8 mm back from the lid front edge, 60 by 20 mm, on 0.3 mm card in a 1 mm recess so a stacked case cannot scratch the window below.

Keep it 6 mm from the case edge or the frame wall whitens on ejection. A 15 by 15 mm colour insert in the lid corner covers five codes with one tool, 0.06 per unit against 0.35 for a dyed shell.

Conclusion

A Small Plastic Case is used by matching one size set to each setting: cell width 48 to 65 mm for kitting, a kit under 3.2 kg, a 2 mm slot gap for accessories. Line up cells, shell and clearance and it holds on the line and the shelf. The Small Plastic Case meets the scene first.

This article discusses only the container (case body) side of specifications and design intent, and does not cover any handling, loading or use of the contents.