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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”.



Section

Packaging

Title


Control No.

PKG-006



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



Section

Packaging

Title


Control No.

PKG-006



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.



Section

Packaging

Title


Control No.

PKG-006



Correct way to stack pallets (Examples)

Returnable Stacked Pallets

Wooden Stacked Pallets



Section

Packaging

Title


Control No.

PKG-006



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.



Section

Packaging

Title


Control No.

PKG-006



Pallet Banding Calculations• Polypropylene banding (1/2" wide band)

• 2 bands per pallet

• (600 lbs. / 2) x 2 bands = 600 lbs. max load


• (600 lbs x / 2) x 3 bands = 900 lbs. max load

• Polyester banding (1/2" wide band)


• (800 lbs. / 2) x 2 = 800 lbs. max load


• (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

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