INTRODUCTION
The function of a cushioned package is to provide a buffer between the product and the world of distribution and handling. To design this interface we must be able to determine the types and severity of the hazards that the package will encounter. These may encompass many things, but the most powerful include drops which occur during handling, vibration of the transportation vehicle, and compressive loads encountered during warehousing.

Once we have identified what inputs to expect from the shipping environment, and to what extent the unpackaged product can withstand these, we can go about making up the difference between these two levels with a cushioned package system.

Ideally, the package system will provide enough protection to exactly match the requirements of the product and distribution environment. There are, however, two pitfalls which may occur if a systems approach to package design is not adopted. In the first situation, the package falls short of the protection requirements and a significant amount of damage occurs during shipment. This "under-packaging" is fairly obvious to detect, but is avoidable and easily corrected with changes to the method of shipment, package design, product design, or combinations of the above. In the second situation little or no damage occurs, but the product is "over packaged". In effect, the package is providing more protection than is required. Just as "under-packaging" wastes money through damaged product and loss of customer good will, "over-packaging" siphons money directly from a company's bottom line.

Try to visualize the general concept of product/package design as the bar chart depicted in Figure 1. The shaded background can be thought of as the level of environmental intensity or severity for a given distribution channel. The product has some inherent ability withstand this abuse, however it usually is not rugged enough to make it through shipment on its own. The role of the package, therefore, is to make up the difference between what the environment has to offer and what the product can withstand. The ideal case, as depicted by the first product/package system bar, is where the package exactly makes up the difference between the product ruggedness and the environmental inputs. If the package falls short, as depicted by the second product/package system bar, "under packaging" has occurred and damage in shipment will most likely result. If the package provides too much protection, as depicted by the third product/package system bar, "over packaging" has occurred and money is being wasted on protection which is not required. In certain instances it will actually be cheaper to ruggedize the product rather than put an expensive package around each unit. This product improvement is depicted in the fourth product/package system bar.