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DENSO

DENSO. Denso Manufacturing Michigan Inc. Production Control Supplier Manual. Control No . PKG-006. Section Packaging. Title Unitization and Palletizing Requirements. Date Issued : 2-23-99 Date Revised : 6/6/13. Purpose:.

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DENSO

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  1. DENSO Denso ManufacturingMichigan Inc. Production Control Supplier Manual Control No. PKG-006 Section Packaging Title Unitization and Palletizing Requirements Date Issued : 2-23-99 Date Revised : 6/6/13 Purpose: To define unitization and palletizing requirements for incoming product. Standards: • 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”. (1) G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements

  2. DENSO Denso ManufacturingMichigan Inc. Production Control Supplier Manual Control No. PKG-006 Section Packaging Title Unitization and Palletizing Requirements Date Issued : 2-23-99 Date Revised : 6/6/13 Sample DMMI Order: Part R: 2 boxes Part B: 1 box Part Y: 3 boxes Part Z: 3 boxes Part G: 2 boxes CORRECT PALLETIZATION Part Y Part Y Part Y Part R Part R Empty Part G Part G Part Z Part Z Part Z 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 (2) G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements

  3. DENSO Denso ManufacturingMichigan Inc. Production Control Supplier Manual Control No. PKG-006 Section Packaging Title Unitization and Palletizing Requirements Date Issued : 2-23-99 Date Revised : 6/6/13 These examples are incorrect! Part G Part R Part Y Part Y Part B 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. (3) G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements

  4. DENSO Denso ManufacturingMichigan Inc. Production Control Supplier Manual Control No. PKG-006 Section Packaging Title Unitization and Palletizing Requirements Date Issued : 2-23-99 Date Revised : 6/6/13 Correct way to stack pallets (Examples) Returnable Stacked Pallets Wooden Stacked Pallets (4) G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements

  5. DENSO Denso ManufacturingMichigan Inc. Production Control Supplier Manual Control No. PKG-006 Section Packaging Title Unitization and Palletizing Requirements Date Issued : 2-23-99 Date Revised : 6/6/13 Incorrect way to stack pallets (Examples) Wooden pallets stacked on top of returnable. • 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. (5) G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements

  6. DENSO Denso ManufacturingMichigan Inc. Production Control Supplier Manual Control No. PKG-006 Section Packaging Title 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 Date Issued : 2-23-99 Date Revised : 6/6/13 * Denotes change End of Procedure (6) G:PRD_CTRL/SUPPLIER MANUAL UPDATES 2009/SUPPLIER MANUAL UPDATES 2011/ Unitization and Palletizing Requirements

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