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DENSO. Denso Manufacturing Michigan Inc. Production Control Supplier Manual. Control No . PKG-006. Section Packaging. Title Unitization and Palletizing Requirements. Date Issued : 2-23-99Date Revised : 6/6/13. Purpose:. - PowerPoint PPT PresentationTRANSCRIPT
DENSODenso Manufacturing Michigan Inc.
Production Control Supplier Manual
Section
Packaging
Title
Unitization and Palletizing Requirements
Control No.
PKG-006
Purpose:
Standards:
Date Issued : 2-23-99 Date Revised : 6/6/13
To define unitization and palletizing requirements for incoming product.
(1)G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements
A) Unitization• Containers must be secured to the pallet for shipping.• See page 6 for banding calculation formulas to determine requirements.• Only polypropylene or polyester banding is allowed.• Red tie bands are also allowed.• Metal banding is prohibited • Two bands should run parallel to the 48” dimension of the pallet. (Recommended tension is 35 lbs.)• Clear strecthwrap may be used if the supplier does not have banding capability.• Opaque (black) stretchwrap is prohibited.• Do not band or wrap 2 pallets together.
B) Palletizing• Palletize totes per the packaging specification – DO NOT exceed specified pallet height.• No pallet can exceed 50”. This allows product to stack two high (or approx. 100”) in the truck for shipping.• When using returnable packaging returnable top and bottom pallets are required.
C) Mixed Pallets• Product can be mixed on a pallet if: DMMI’s orders are less full pallets The mixed pallet is labeled as “MIXED” on 2 sides (See Labeling Section)• “Like” part numbers must be consolidate on one pallet.• If a mixed pallet is uneven on the top layer, empty boxes / totes must be added to cube the uneven layer.• Empty boxes / totes MUST be labeled as “empty”.
DENSODenso Manufacturing Michigan Inc.
Production Control Supplier Manual
Section
Packaging
Title
Unitization and Palletizing Requirements
Control No.
PKG-006
Date Issued : 2-23-99 Date Revised : 6/6/13
(2)G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements
Sample DMMI Order:Part R: 2 boxesPart B: 1 box
Part Y: 3 boxesPart Z: 3 boxesPart G: 2 boxes
CORRECT PALLETIZATION
Part Z Part Z Part Z
Part R Part R Empty
Part G Part G Part B
• Like parts are together• Mixing of different tote sizes is allowed *• Mixed pallet height can be up to 50”, when applicable *• Both pallets are stable• An empty box is used to cube top layer of mixed pallet
Part Y Part Y Part Y
DENSODenso Manufacturing Michigan Inc.
Production Control Supplier Manual
Section
Packaging
Title
Unitization and Palletizing Requirements
Control No.
PKG-006
Date Issued : 2-23-99 Date Revised : 6/6/13
(3)G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements
These examples are incorrect!
Part Y Part Y Part B
Part G Part R
Part Y Part R Part G
• Like parts are not together• Pallet on left is unstable
D) Expendable Back-up Shipments• When shipping back-up containers, ship on returnable pallets, if available.• Returnable top and bottom pallets required.• Returnable unitization required.• If returnable pallet is not available, use approved wooden pallets (see Expendable Packaging Requirements)• Do not mix returnable pallets and expendable (wooden) pallets in a single stack.
DENSODenso Manufacturing Michigan Inc.
Production Control Supplier Manual
Section
Packaging
Title
Unitization and Palletizing Requirements
Control No.
PKG-006
Date Issued : 2-23-99 Date Revised : 6/6/13
(4)G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements
Correct way to stack pallets (Examples)
Returnable Stacked Pallets
Wooden Stacked Pallets
DENSODenso Manufacturing Michigan Inc.
Production Control Supplier Manual
Section
Packaging
Title
Unitization and Palletizing Requirements
Control No.
PKG-006
Date Issued : 2-23-99 Date Revised : 6/6/13
(5)G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements
Wooden pallets stacked on top of returnable.
Incorrect way to stack pallets (Examples)
• It is unacceptable for wooden pallet loads to be stacked on top of returnable pallet loads. Concern with wooden pallets sliding off of the returnable pallets because the pallets do not interlock.• It is unacceptable for returnable pallet loads to be stacked on top of wooden pallets.
DENSODenso Manufacturing Michigan Inc.
Production Control Supplier Manual
Section
Packaging
Title
Unitization and Palletizing Requirements
Control No.
PKG-006
Date Issued : 2-23-99 Date Revised : 6/6/13
(6)G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements
Pallet Banding Calculations• Polypropylene banding (1/2" wide band)
• 2 bands per pallet
• (600 lbs. / 2) x 2 bands = 600 lbs. max load
• 3 bands per pallet
• (600 lbs x / 2) x 3 bands = 900 lbs. max load
• Polyester banding (1/2" wide band)
• 2 bands per pallet
• (800 lbs. / 2) x 2 = 800 lbs. max load
• 3 bands per pallet
• (800 lbs. / 2) x 3 = 1200 lbs. max load
Do not use polyester banding where polypropylene must be used.
• Formula
• Conservative calculation = (Strength / 2) x (Number of straps applied) =
max load weight
End of Procedure* Denotes change