Académique Documents
Professionnel Documents
Culture Documents
734-983-1000
1 of 24
2.1
YAOM-PES12-015W
11/12/10
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734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
TABLE OF CONTENTS
1.0 2.0 SCOPE ALLOWABLE CARTON DIMENSIONS
2.1 2.2 2.3 Allowable Dimensions & Minimum Board Strengths Bulk Cartons Cartons Loading Diagrams
3.0
4.0 5.0
pg. 10 pg. 12
pg. 12 pgs. 12-14
6.0
PALLETIZATION
6.1 6.2 6.3 6.4 General Requirements Stretch Wrap Banding Palletization of Cartons on Pallet
pg. 14
pg. 14 pg. 14 pg. 15 pgs. 15, 16
pg. 17
pg. 17
SHIPMENT DAMAGE
8.1 Damage Documentation and Resolution
pg. 17
pg. 17
LABELING
9.1 9.2 9.3 Carton Labeling Mixed Pallet Loads Master & Mixed Loads: General Info
pg.18
pg.18 pgs. 18-21 pg. 22,23
10.0 ENVIRONMENTAL POLICY AND SOCS 11.0 PACKAGING QUESTIONS & ISSUES
pg. 24 pg. 24
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
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1.0
SCOPE
The Yazaki Component Supplier Packaging Guideline for Standard Parts outlines the minimum requirements for packaging systems of the following component families: o o o o o o o Tape / Foam Clips / Fasteners Nuts / Bolts / Screws Connectors Relays Grommets Some Shields & Brackets
Standard Parts are hereby defined as: parts which are small and/or uniform in configuration which will fit into a pre-determined set of hand-held/human moveable carton dimensions. These minimum requirements shall be met by all component suppliers shipping standard parts to Yazaki North America. (Non-Standard part packaging requirements are discussed in Yazakis Component Supplier Packaging Guideline for Non-Standard Parts.) The packaging systems contained within this document will be used primarily in sea containers (40, 40 High Cube, and 45) and shipped overseas to Yazaki manufacturing locations throughout the world. Component Supplier packaging must be robust so that it withstand the rigors of extended overseas transportation (30+ days in transit) through warm/humid climates while also fully utilizing trailer and sea container space to minimize transportation costs. It is ultimately the Component Suppliers responsibility to ensure that their parts arrive at the end Yazaki manufacturing location undamaged. Suppliers must use packaging that withstands the various dynamics of all transportation methods for land, air and sea.
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
2.0
Burst Strength (psi) 200# 250# 275# 350# 200# 275# 350# 400#
Remarks Do Not Use / Not Allowed Do Not Use / Not Allowed Min. Single Wall Requirement Elevated Strength Single Wall Do Not Use / Not Allowed Min. Double Wall Requirement Elevated Strength Double Wall Elevated Strength Double Wall
Convolute Tubing
Terminal Reels
SW
(L)
48 x 45 Wooden Pallet (+ 0 / - 0.5")
11 1/4 x x x x x x x x x x x x x x x
(W)
6 11 1/4 11 1/4 12 12 11 1/4 22 1/2 22 1/2 15 15 22 1/2 22 1/2 22 1/2 45 45 x x x x x x x x x x x x x x x
(H)
5 5 10 5 10 10 10 15 10 15 10 15 20 ? ?
Hand-Held
12 12 22 1/2 22 1/2 24 24 24 48 48 48 48 48 ? 45
Standard Packaging
SW SW SW SW SW SW
SW SW SW
DW DW DW
SW SW SW SW SW SW SW SW
SW SW SW SW SW SW SW SW
SW SW SW SW SW SW DW DW DW DW DW DW DW DW
SW SW SW SW SW SW DW DW DW DW DW DW DW X
Bulk
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
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Single Wall cartons shall be constructed of C-Flute linerboard. Double Wall cartons shall be constructed of B-C Flute linerboard.
SINGLE WALL CARTON BOARD FLUTE REQUIREMENT (C-FLUTE) DOUBLE WALL CARTON BOARD FLUTE REQUIREMENT (B-C FLUTE)
There are no exceptions to these minimum requirements. Cardboard strengths less than the stated rating and flute are not sufficiently strong enough to withstand overseas shipments and possible multiple handlings by the freight carriers. Yazaki Packaging Engineering will contact the Component Supplier directly and work with them when packaging damage is chronic. Certain product families and cartons sizes may require stronger board strengths when the required minimum board strength is found to be insufficient. Carton heights other than 5, 10, 15 or 20 are NOT allowed. o Yazakis reasoning for requiring standardized heights of all incoming packaging is because mixed pallet loads for outbound shipments must be built from numerous component suppliers products/packaging. A Component Suppliers own pallet load of parts is frequently dismantled, and new pallet loads are reassembled with various other cartons from other Component Suppliers to meet order requirements for Yazakis manufacturing locations. Standardized carton heights make it easier to assemble mixed pallet loads and keep carton layering level on the mixed pallet loads.
The Ergonomic Weight Limit for Hand-Held cartons is 30 Lbs (weight of empty carton, interior dunnage, & product combined).
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
2.2
BULK (LARGE/LONG) CARTONS Certain Standardized Parts, such as long plastic shields, may require using longer carton footprints in order to fit the part correctly. Yazaki allows the use of 48 x 22 and 48 x 15 carton footprints with the specified heights shown in the table in Section 2.1. If the part is longer than 48, carton footprints should be sized so that the 45 side of the pallet is maintained so that an X x 45 pallet can be loaded 2 across in a sea container (i.e., carton widths of 11 , 15, 22 with carton lengths as long as required for the part to fit). Allowable Bulk Carton heights are 10, 15, and 20 (+/- 0.25). CARTON LOADING DIAGRAMS The diagram below details the layering method on the pallet for the required carton footprints on the 48 x 45 pallet:
2.3
12" x 11 1/4"
12 x 11.25 12 x 11.25 12 x 11.25 12 x 22.5
22 1/2" x 12"
24" x 11 1/4"
24 x 11.25 24 x 11.25
24" x 22 1/2"
12 x 22.5
12 x 22.5
24 x 22.5
24 x 22.5
6x 11.25
6x 6x 11.25 11.25
6x 11.25
6x 11.25
6x 6x 11.25 11.25
6x 11.25
12 x 11.25
12 x 11.25
12 x 11.25
12 x 11.25
45"
6x 11.25 6x 6x 11.25 11.25 6x 11.25 6x 11.25 6x 6x 11.25 11.25 6x 11.25 12 x 11.25 12 x 11.25 12 x 11.25 12 x 11.25 12 x 22.5 6x 11.25 6x 6x 11.25 11.25 6x 11.25 6x 11.25 6x 6x 11.25 11.25 6x 11.25 12 x 11.25 12 x 11.25 12 x 11.25 12 x 11.25 12 x 22.5 12 x 22.5 12 x 22.5 24 x 11.25 24 x 11.25 24 x 11.25 24 x 11.25 24 x 22.5 24 x 22.5
48"
BULK CARTONS
48" x 22 1/2" 48" x 15"
48 x 15 48 x 22.50
48 x 15
48 x 22.50 48 x 15
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
3.0
OF
BOX
AM
CI
TY A
ND
ERE STATE IN H
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
The manufacturers joint for carton seam closure is preferred to be glued. Staples are acceptable as long as no part of any staple is protruding out from the carton material (staples create possible snag points for parts and injury concerns). o If stapling the manufacturers joint, metal staples should be no less than 0.103 wide and 0.023" thick.
Manufacturer's Joint (Glue Preferred, Staples allowed)
Cartons should be closed with tape at every location flaps meet with each other and with the main carton body. At least 6 tape locations shall be used per RSC carton.
6 5 4
3 2 1
734-983-1000
9 of 24
2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
3.2
CARTON CORNER POSTS To ensure stacking strength, carton corner posts may be used inside of cartons (hand-held and bulk) when increased packaging strength is deemed necessary. Compressed Circular (paper tubes) and Triangular Posts (Double Wall Cardboard) may be used inside of any carton to provide additional stacking strength.
If used internally, corner posts should be installed using wide masking tape as shown in diagram below. Use a minimum of three spot tapes to secure each corner post.
2 3/4" Masking Tape Minimum of 3 Tapes per Corner Post 1 RSC CARTON
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
Laminated L-Shaped posts are not preferred inside of cartons because they do not provide adequate support due to lack of surface area, but may be used externally on pallet loads to provide stability if necessary.
L-Shaped Corner Posts should set on top of wooden pallet and be as tall as the entire pallet load. Corner Posts should be contained inside of Stretch Wrap.
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
4.0
80% (H)eight
90%
(W)idth (L)ength
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
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5.0
PALLET CONSTRUCTION
5.1 PALLET DIMENSIONS Yazaki strives for maximum utilization of sea container and trucking trailers. The best overall pallet footprint for full utilization of these conveyances is 48 x 45. All component suppliers of Standardized Parts are required to ship product on 48 x 45 pallets. o Exceptions will be reviewed and may be given to a supplier whos shipping volumes do not fulfill full layers or full pallet loads on the 48 x 45 pallet, or whos product type requires specialized packaging/dimensions. o NOTE: Suppliers whos shipment volumes which do not warrant the use of the 48 x 45 pallet (example: supplier normally ships parts via UPS) are still required to ship their product in carton sizes which would cube/fit the 48 x 45 pallet and meet the carton height requirements previously stated in this document. 5.2 MATERIALS & CONSTRUCTION Required pallet footprint with tolerances shall be 48 x 45 Stringers 48 (+0 / -1/4) Deck Boards 45 (+0 / -1/4)
Pallets must provide a 4-way fork entry and be of double face non-reversible wood construction. Pallets other than wood construction are to be reviewed and approved by YazakiPackaging Eng. Dept. When shipping on wooden pallets, shipping documentation must include a notation that states: "THIS SHIPMENT CONTAINS WOOD PACKAGING MATERIAL WHICH MEETS THE ISPM 15 STANDARDS AND IS MARKED ACCORDINGLY." Do not use pallets with rotted or decayed lumber, knots/knotholes, bark, or splintered wood. Check for splits that will affect holding strength or interfere with nailing.
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
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All nails should be flush to surface of wood or recessed slightly. Recycled pallets which are not sound or that are not within the tolerances (+ 0 / - 0.25) of the required pallet footprint of 48 x 45 are not allowed. Do not use wooden pallets which show signs of insect infestation. Pallet quality is the foundation for ensuring overall packaging system quality and minimizing packaging system failures. o All wooden pallets used to ship product to Yazaki North America must meet ISPM 15 - Guidelines for Regulating Wood Packaging Material in International Trade and be stamped with the certified marking as shown. o The required Yazaki pallet footprint is shown below.
The combined surface area of deckboards must be equal to or greater than 50% of the actual surface area of the pallet footprint. In example above, deckboard widths are 4, 4, 8, 4, & 4 = 24. Length of pallet is 48. 24 x 45 / 48 x 45 = 50% surface coverage and is technically acceptable. Larger surface coverage is preferred. This
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
requirement provides adequate support for the bottom layer of cartons so that they do not drop between the deckboards and cause failure/crushing of the entire pallet load or allow spearing of the undersides of cartons by hi-lo forks.
6.0
PALLETIZATION
6.1 GENERAL REQUIREMENTS Maximum pallet load height of cartons + the pallet should be no higher than 50. As previously stated, allowable hand-held carton heights are 5, 10, and 15. Allowable Bulk carton heights are 10, 15, and 20. These heights are required to make an overall pallet load height of 50. Yazaki allows its Component Suppliers to select the best carton footprint (L x W) of their product. Carton footprints selected shall cube/fit to within 1 of the length and 1 of the width of the 48 x 45 pallet. Carton footprints should completely cube out a full layer on the pallet with no overhang. STRETCH WRAP The use of stretch wrap to secure the cartons to the pallet is preferred. The stretch wrap should start at the floor and include all 4 corners of the pallet multiple times (3+ times each corner) in order to fully secure the pallet and minimize shifting of the cartons in transit. Required application is a minimum of one layer of stretch film covering 100% of UL with all seams overlapped a minimum 40%. Edges of top layer of cartons must be covered on all 4 sides as shown below.
Entire top edge of cartons covered with stretch wrap Stretch Wrap overlaps minimum of 40% per wrap
6.2
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
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6.3
BANDING If banding is used, the banding (minimum 0.5 wide x 0.021 thick) must be extruded Nylon Polypropylene, or made of pre-elongated (oriented) material and able to contract upon itself the extent of its stretch created upon application. Steel banding is NOT ALLOWED for Standard Item Components. A minimum of 4 banding straps should be used (2 for length, 2 for width direction of pallet). Additional banding straps (5 or more) should be used if the cartons being palletized are not in a 2 x 2 layer arrangement on the pallet in order to secure each column of cartons on the pallet. Fusing straps or crimp seals should be used to secure banding. Use of buckles is not acceptable unless approved by Yazaki Packaging Engineering Dept.
6.4
PALLETIZATION OF CARTONS ON PALLET A Pallet Load packaging system shall withstand a stacking height of 100 (2 Pallet Loads high) in transit and arrive in a satisfactory condition at the final point of use (Mexico or Asia). All container systems shall have sufficient structural integrity to support normal handling and storage. Carton integrity must be maintained so pallet loads can be safely stacked in static (non-transit) storage three pallet loads high or to a height of 12 6, whichever is greater. Cartons must NOT overhang the pallet base at any location. Overhanging cartons destroy the vertical stacking strength of the entire pallet load and facilitate crushing of the cartons. Overhanging Cartons can lose up to 50% of their vertical stacking strength.
No Overhang allowed!
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2.1
YAOM-PES12-015W
11/12/10
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At least 2 opposite edges of carton MUST be completely supported by the top deckboards of pallet so that all 4 corners of the carton rest upon the deckboards. Any carton that is floating or suspended with less than two edges of the carton fully supported by the deckboards creates the risk of dropping through the deckboards and causing the unit load to fail. Cartons gain the majority of their stacking strength from their corners. If carton sizes selected are not sufficiently supported on two opposite edges by the deckboards of the pallet, a single layer of 48 x 45 cardboard that is no larger than the pallet shall be used between the pallet and the bottom layer of cartons to ensure an even layer and that the cartons do not drop between the deckboards.
OK
NOT OK
Cardboard Layer Pad
OK
NOT OK
Always make sure to stack pallet loads so that the support (vertical walls and corners) of the cartons support each other in straight alignment. Palletizing Cartons in staggered/brick layering fashion is not allowed.
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2.1
YAOM-PES12-015W
11/12/10
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7.0
8.0
SHIPMENT DAMAGE
8.1 DAMAGE DOCUMENTATION & RESOLUTION Yazaki Components Warehouse documents all incoming packaging and product damage from all Component Suppliers. Yazaki Warehouse & Packaging Engineering will investigate & determine the cause of damage (carrier vs. supplier packaging) and alert the Component Supplier if it is decided that the Component Suppliers packaging is not sufficient and needs to be improved. The Component Supplier & Yazaki Packaging Engineering shall work together on a packaging improvement plan in order to achieve resolution. Packaging Trials may be required to ensure positive effects before full implementation of an improved packaging system. If a packaging improvement plan is not worked towards, followed or achieved in a timely manner by the Component Supplier: o GQRS reports and/or charge backs for damaged packaging & product may be issued to the Component Supplier. o Component Supplier Rating may be affected.
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
9.0
LABELING
9.1 CARTON LABELING Each carton shall be labeled with 2 labels on adjacent corners as shown below:
NO GOOD: Labels are on opposite sides of carton OK! NO GOOD!
OK!
NO GOOD!
Refer to YAOM-PE-S12-014W YNA Component Supplier Carton Barcode Label Guideline for specific carton barcode labeling format and design requirements.
9.2
MIXED PALLET LOADS: ALLOWABLE SITUATIONS & LABELING Mixed Loads (pallets with multiple part numbers): o Are allowed if the Yazaki order of one part number is not enough to complete a full pallet load of that part number. o Are allowed if the Cartons used to ship product to Yazaki are very small in nature and do not take up a complete layer on the pallet. o The same part number from the same order # should be kept on the same pallet to create a full pallet load of that part number. Leftover cartons from this part number which do not complete the next full pallet load may be used to make a Mixed Pallet Load with additional leftover cartons/part numbers.
734-983-1000
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
The following methodology shall be followed by the component supplier when palletizing orders for a Yazaki Distribution Center: o Final Mixed Load Pallets with multiple part numbers shall be packed so that the same part numbers are grouped together on the pallet as shown below: MIXED PALLET LOAD
B A A B C
C B C C B
NO GOOD! Part numbers are not stacked together. Same part levels are all over in pallet.
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2.1
YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
o Pallet loads from the same order should be packed completely with the same part number completing as much of a pallet as possible before adding more part numbers. Final pallet(s) should be mixed pallet as shown by Pallet Load #2.
Pallet Load #1
Back Column, 3 boxes, hidden Back Column, 3 boxes, hidden
Pallet Load #2
B B B B B
A A A A B
B B B
OK! Pallet Load #1 is completed with "B" Level parts. Mixed Pallet Load #2 contains all "A" level parts + 1 carton of "B" level parts (which would not fit on pallet #1) and 1 carton of "C" level parts.
Pallet Load #1
Back Column, 3 boxes, hidden Back Column, 3 boxes, hidden
Pallet Load #2
B A A A B
A B B B B
NO GOOD! Pallet #1 should be completely filled with Part "A" before beginning to palletize Pallet #2.
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YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
o Mixed Pallet Loads from different order numbers are NOT ALLOWED. The example below illustrates 2 order numbers shipped on the same truck. ORDER #1: ORDER #2:
B B B B B
A A A A C
B B B
E E E D E
F F F F F
F F F F F
E F
F A
D A D
E F
Mixed Pallet Load #3 from Order #1 contains mixed part numbers from 2 different orders. Mixed Pallet Load #3 from Order #2 contains mixed part numbers from 2 different orders. Both Pallet Load #3's are unacceptable.
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YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
9.3
MASTER & MIXED LOAD GENERAL INFO MASTER PALLET LOAD LABEL o A Master Pallet Load label shall be used to identify the total quantity of parts on the pallet when the part number shipped on the pallet is the same. o The serial number area of the Master Load Label shall contain the following information for each carton on the pallet: Part Number Quantity (total pieces on pallet) Serial Number of each carton on the pallet MIXED PALLET LOAD LABEL o A Mixed Pallet Load label shall be used to identify the quantities and part numbers shipped when there are multiple part numbers on the pallet. o The serial number area of the Mixed Pallet Load label shall contain the following information for each carton on the pallet: Part Number Quantity of that part number Serial Number of the carton MASTER & MIXED PALLET LOAD LABEL LOCATIONS o There shall be a minimum of 1 Master or Mixed labels for each pallet shipped. o The label location shall be on the bottom layer of cartons on the pallet, with the Master or Mixed label facing the loading direction into the trailer for easy visibility. o Master & Mixed labels shall be placed in such a manner that when the pallet load is broken down, the Master/Mixed label remains on the pallet load until the very last layer of cartons is accessed. If the pallet is banded: The banding shall not cover the Master/Mixed label. The Master/Mixed label shall not be placed over the banding. If the pallet is stretch-wrapped, the Master/Mixed label shall be placed underneath the stretch-wrap on the bottom layer of cartons. o Master Load Labels and Mixed Load Labels shall be placed so that they do not cover any of the cartons barcode (handling unit) labels.
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YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.
o The diagrams below illustrate the placement of the Master and Mixed Load Labels on the final pallet load.
BANDED PALLET
STRETCHWRAPPED PALLET
Master/Mixed Label placed on bottom layer of cartons so that it is clearly visible, not covering carton (handling unit) labels, and not over the banding.
Master/Mixed Label placed on bottom layer of cartons underneath stretchwrap so that it is clearly visible and not covering carton (handling unit) labels
Master OR Mixed Labels in BOTTOM position on pallet in position that will NOT destroy the label after banding or stretchwrap is removed. (Label is NOT placed over banding OR label is inside of stretchwrap)
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YAOM-PES12-015W
11/12/10
This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.