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DENSO Denso Manufacturing Michigan Inc. Production Control Supplier Manual Section Packaging Title Unitization and Palletizing Requirements Control No.

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Presentation on theme: "DENSO Denso Manufacturing Michigan Inc. Production Control Supplier Manual Section Packaging Title Unitization and Palletizing Requirements Control No."— Presentation transcript:

1 DENSO Denso Manufacturing Michigan Inc. Production Control Supplier Manual Section Packaging Title Unitization and Palletizing Requirements Control No. PKG-006 Purpose: Standards: Date Issued : 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”.

2 DENSO Denso Manufacturing Michigan Inc. Production Control Supplier Manual Section Packaging Title Unitization and Palletizing Requirements Control No. PKG-006 Date Issued : 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 boxes Part B: 1 box Part Y: 3 boxes Part Z: 3 boxes Part G: 2 boxes CORRECT PALLETIZATION Part Z Part R Empty 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

3 DENSO Denso Manufacturing Michigan Inc. Production Control Supplier Manual Section Packaging Title Unitization and Palletizing Requirements Control No. PKG-006 Date Issued : 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 B Part GPart R Part YPart RPart 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.

4 DENSO Denso Manufacturing Michigan Inc. Production Control Supplier Manual Section Packaging Title Unitization and Palletizing Requirements Control No. PKG-006 Date Issued : 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

5 DENSO Denso Manufacturing Michigan Inc. Production Control Supplier Manual Section Packaging Title Unitization and Palletizing Requirements Control No. PKG-006 Date Issued : 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.

6 DENSO Denso Manufacturing Michigan Inc. Production Control Supplier Manual Section Packaging Title Unitization and Palletizing Requirements Control No. PKG-006 Date Issued : 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


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