component supplier packaging and shipping guideline

YNCA Business Management Systems Region / Dept.

YNCA / SCM GUIDELINE/SPECIFICATION Component Supplier Packaging &

Shipping Guideline Revision Date:

AA‐SC‐xx‐G‐01 2016‐MAR‐31

CONFIDENTIAL: This information is Yazaki property and can only be distributed to formal business partners or parties authorized by the signing of non‐disclosure agreements. Copies are uncontrolled and subject to YA‐01‐01 Documentation and Records Policy.

https://www3.yncaonnection.com/sites/qm/msd/YA‐01‐01‐06 Guideline or Specification Template (English).dotx Print Date: 2016‐MAR‐31 of 47

Component Supplier Packaging and Shipping Guideline







TABLE OF CONTENTS I. SCOPE ............................................................................................................................................................. 5

II. PACKAGING SYSTEM DIMENSIONS ................................................................................................................ 6

A. PALLET DIMENSIONS ............................................................................................................................... 6

B. CARTON DIMENSIONS ............................................................................................................................. 6

III. GENERAL CARTON CONSTRUCTION REQUIREMENTS .................................................................................... 7

A. CARTON DESIGN ...................................................................................................................................... 7

IV. LABELING ........................................................................................................................................................ 8

A. LAYOUT .................................................................................................................................................... 8

V. PALLET CONSTRUCTION ............................................................................................................................... 15

VI. PALLETIZATION ............................................................................................................................................. 15

A. GENERAL REQUIREMENTS ..................................................................................................................... 15

B. MASTER PALLET LOAD LABEL ................................................................................................................ 16

C. MIXED PALLET LOAD LABEL ................................................................................................................... 16

D. MASTER & MIXED PALLET LABEL DESIGN ............................................................................................. 16

VII. SEA CONTAINER AND TRUCK TRAILER LOADING ......................................................................................... 17

A. LOAD CONFIGURATION ......................................................................................................................... 17

B. LOADING REQUIREMENTS .................................................................................................................... 17

VIII. COMPONENT PACKAGING DATA FORM ...................................................................................................... 18

A. PURPOSE ............................................................................................................................................... 18

IX. SUPPLIER TEST SHIPMENTS .......................................................................................................................... 19

A. TEST SHIPMENT CRITERIA ..................................................................................................................... 19

1) Reasons for Test Shipments ............................................................................................................................. 19

X. SHIPMENT DAMAGE .................................................................................................................................... 19

A. DAMAGE DOCUMENTATION & RESOLUTION ....................................................................................... 19

XI. PACKAGING QUESTIONS & ISSUES ............................................................................................................... 20

XII. APPENDIX A .................................................................................................................................................. 21

A. PREFERRED CARTON DIMENSIONS AND SPECIFICATIONS .................................................................... 21







B. SPECIAL PACKAGING SYSTEMS .............................................................................................................. 23

1) WIRE SPOOLS / NPS’ ........................................................................................................................................ 23

2) WIRE FIBER DRUMS ......................................................................................................................................... 24

3) TERMINAL REEL CARTONS ............................................................................................................................... 25

4) CONVOLUTE TUBING ....................................................................................................................................... 26

XIII. APPENDIX B .................................................................................................................................................. 27

A. DUNNAGE OPTIONS .............................................................................................................................. 27

1) CARTON CORNER POSTS .................................................................................................................................. 27

XIV. APPENDIX C .................................................................................................................................................. 28

A. BAR CODE SYMBOLOGY ........................................................................................................................ 28

1) Code Configuration .......................................................................................................................................... 28

2) Code Density and Dimension ........................................................................................................................... 28

3) Reflectivity and Contrast .................................................................................................................................. 29

B. DATA AREAS AND TITLES ....................................................................................................................... 29

1) Data Identifiers ................................................................................................................................................ 29

2) Part Number Area (P) – (Required: Bar Code and Human Readable Format) ................................................ 29

3) Quantity Area (Q) – (Required: Bar Code and Human Readable Format) ....................................................... 29

4) Supplier Number Area (V) – (Optional: Bar Code and Human Readable Format) ........................................... 30

5) Serial Number Area (S) – (Required: Bar Code and Human Readable Format) ............................................... 30

6) Part Description – (Required: Human Readable Format) ................................................................................ 31

7) Carton Weight – (Required: Human Readable Format) ................................................................................... 31

8) MFG Date – (Required: Human Readable Format) .......................................................................................... 31

9) Free Area – (Required: Ship To / Rev LVL) ....................................................................................................... 31

10) Supplier PN (2P) – (Optional, bar code and human readable format is preferred) ................................. 31

11) Assembled In / Country of Origin & Component Supplier Name (Required: Human Readable) ............ 32

XV. APPENDIX D .................................................................................................................................................. 32

A. PALLET CONSTRUCTION ........................................................................................................................ 32

XVI. APPENDIX E .................................................................................................................................................. 34







A. PALLETIZATION LABEL PLACEMENT ...................................................................................................... 34

B. PALLETIZATION OF CARTONS ON PALLET ............................................................................................. 34

C. MIXED PALLET LOADS: ALLOWABLE SITUATIONS ................................................................................. 36

D. MASTER / MIXED LABEL REQUIREMENTS ............................................................................................. 39

E. MASTER & MIXED PALLET LOAD LABEL LOCATIONS ............................................................................. 40

A. ..................................................................................................................................................................... 40

F. STRETCH WRAP ..................................................................................................................................... 41

G. BANDING ............................................................................................................................................... 42

XVII. APPENDIX F .................................................................................................................................................. 43

A. BRACING ................................................................................................................................................ 43

B. BRACING EXAMPLES .............................................................................................................................. 45

C. AIR BAGS................................................................................................................................................ 46

D. WOODEN BRACING ............................................................................................................................... 46

XVIII. DOCUMENT HISTORY ................................................................................................................................... 47







I. SCOPE

• The Yazaki Component Supplier Packaging & Shipping Guideline outlines the minimum requirements for packaging systems for the component families listed below as well as any other components that may not be listed:

Standard Parts:

Tape / Foam Clips / Fasteners Nuts / Bolts / Screws Connectors Relays Grommets Small Shields & Brackets

Non-Standard Parts:

Wire Spools Terminal Reels Convolute Tubing Extended Length Plastic Shields/Troughs

• 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.

• Non-Standard Parts are hereby defined as: parts which require their own specialized packaging systems and/or carton and pallet dimensions due to part configurations/sizes in order to ensure package and part integrity.

The minimum requirements within these guidelines shall be met by all component suppliers

shipping Standard & Non-Standard Parts to Yazaki.

• The packaging systems contained within this document will be used primarily in truck trailers (48’ and 53’) as well as sea containers (20’, 40’, 40’ High Cube, 45’, and 45’ High Cube). 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 Supplier’s 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. Only one part number is permitted to be shipped inside each box. Multiple part numbers inside one box is NOT PERMITTED.







II. PACKAGING SYSTEM DIMENSIONS

A. PALLET DIMENSIONS

• It is preferred that all Component Suppliers shipping Standard and Non-Standard Parts use a 48” x 45” pallet and cartons or packaging systems which match this pallet. Pallet load height including pallet should be no higher than 50” with proper securement methods of securing the boxes to the pallet.

Due to the size and/or configuration of some Non-Standard Parts, it is understood by Yazaki

that certain packaging systems with special pallet dimensions must be used to ensure the quality of the part.

B. CARTON DIMENSIONS

• Preferred carton dimensions and Non-Standard Part packaging are listed in Appendix A. Component Suppliers can work with the Yazaki Component Packaging Specialist to design appropriate packaging if certain size boxes are not shown in the table.

• Certain Non-Standard Parts (ex: long plastic shields) may require using cartons with longer than 48”

lengths in order to fit the part correctly. If the part itself is longer than 48”, carton footprints should still be sized so that the 45” side of the pallet is maintained so that the pallets can be loaded 2 across in a truck trailer or sea container.







III. GENERAL CARTON CONSTRUCTION REQUIREMENTS

A. CARTON DESIGN

• All cartons (Hand-Held & Bulk) shall be RSC (Regular Slotted Cartons) with flaps for closure. HSC Style Cartons (removable lid) are NOT allowed.

• Hand holes should NOT be used, unless specified by Yazaki Component Packaging Specialist.

If hand holes are required, Yazaki Packaging will notify the component supplier of the hand hole requirement.

• Corrugated cartons shall be designed to withstand 90% humidity at 30°F - 150°F exposure

during handling, extended (40+ days) transit and storage.

• Corrugated box material shall be 100% recyclable. Rice paper or yellow corrugated is not allowed.

• All corrugated cartons MUST have a manufacturer's certificate with ECT (Edge Crush Test) or Burst Strength visible on the bottom of the assembled carton as shown:

• Please see Appendix B for dunnage options

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IV. LABELING

A. LAYOUT

• Yazaki is using a material handling system based on SAP for its Warehouse Management System (WMS) in all its locations and warehouses receiving components and raw materials. In support of this initiative, all component and raw material suppliers that supply to Yazaki or any of its affiliate locations are required to provide bar code labels on each carton or handling unit of product shipped to Yazaki. Appendix C outlines the specific requirements that shall be adhered to by the component supplier.

• Two labels required per box on adjacent sides and at least one label visible when stacked on a pallet.

5ØØ

ASSEMBLED IN THE UNITED STATESCIRCUIT CONTROL CORPORATION

PETOSKEY, MI

SUPPLIER NUMBER (V) 1234567

PART DESCRIPTIONWIRING TERMINALS

MFG DATEØ6 / Ø1 / 2ØØ9

FREE AREA SHIP TO: / REV LVL:

CARTON WEIGHT (Kg)13.6

SUPPLIER PN(2P) A244597

FREE AREA SHIP TO: / REV LVL:

6.0" - 7.0"

4.5" - 5.5"

0.1" (2.5mm) 0.1" (2.5mm)

0.2" (5mm)

SERIAL NO.(S) 1234567cy1A3B5C7D9

0.2" (5mm)

0.25" (6.4mm) Minimum "Quiet Zone" between Bar Code and Line Separations for all barcodes

0.5" (13mm)

0.5" (13mm)

0.5" (13mm)

PART NO(P) 713737Ø233

12 x 11.25 0.5" (13mm) 0.5" (13mm)

Text and Bar Code data areas for:Part No. / Quantity / Serial No / Part

Description / Carton Weight / Mfg. Date / Assembled In Location / are REQUIRED

in the formats presented in guideline. All other data areas are OPTIONAL.

NOTE: ALL text and bar codes should be printedin black.

QUANTITY(Q)







• SAP Supplier Account Numbers that are less than 7 digits shall be preceded by one or multiple zeroes (Ø’s) as necessary to complete the first 7 spaces of the overall Serial Number. Examples for 1 digit, 4 digit, and 7 digit Serial Number Prefixes:

1 is SAP Supplier Account Number - Serial Number always starts as ØØØØØØ1.

1234 is SAP Supplier Account Number - Serial Number always starts as

ØØØ1234.

1234567 is SAP Supplier Account Number - Serial Number always starts as 1234567 without any zeroes preceding the SAP Supplier Account Number.

• The next two digits, as designated by the “cy” in the bar code example, shall be the last two

digits of the calendar year that the part is manufactured in.

• The remaining 7-9 digits of the serial number shall be generated by the component supplier. These 7-9 digits may be alpha-numeric as shown in the diagram below. Using the carton number itself is recommended, but not required. If the carton number is selected to be used, and is for example: carton # 143, the remaining portion of the unique serial number should be ØØØØ143, ØØØØØ143, or ØØØØØØ143, or may use any combination of the carton number plus alpha numeric characters.







• The diagram below explains details for the Serial No. area:

• Each Component Supplier will be responsible for tracking the Serial Numbers they generate for each carton shipped to Yazaki. Any communications to Yazaki about particular cartons (e.g., for rework or quality issues) must include the serial number that appears on the bar code label.

• Each component supplier is responsible for generating serial numbers that are unique across all

of their part numbers and handling units.

• A serial number shall never be repeated.

• ASN’s are required for each shipment and must include all information pertaining to the material on the shipment.

A warning letter will be issued for the first non-compliant labeling issue. Failure to implement needed changes within a month’s time or failure to supply a corrective action plan will result in debit charges. For debit charge schedule please see Yazaki’s Supplier Manual.

1234567 = Supplier's 7 DigitSAP Supplier

Account Number. SAP Supplier AccountNumbers less than 7

digits shall beproceeded by Ø's inorder to make the

entire SAP SupplierAccount Number 7

total digits long.

cy =Last two numbersof Calendar Year

that part was manufactured in.

EX: Partmanufactured in

2009 would required"Ø9" to be placed in

"cy" location.


1A3B5C7D9 =Supplier's Unique

Tracking #.EX: Unique Tracking #

may be partial Yazaki part number

with actual carton number. Part number may also usealpha numeric characters

such as A, B, etc.







Requirements for Ship to Location & Revision Level

• Yazaki has added the additional requirements to the label:

“Ship To” location (Destination Plant or DC)

“Revision Level” of the part (if applicable)

The “Ship To” location and “Revision Level” may be printed in the “Free Areas” on the label. The “Revision Level” may also be printed as shown in Example A in the label examples after the location chart.

• The “Ship To” location should be printed in human readable format, and is based off of the coded location chart below:

SAP Plant Code

Plant / Ship To Location Text to be printed on Label in "Ship To Data Area"

SAP Plant Code


1537 AAMSA Durango Distribution Center Durango Mexico

AMS DDC 5140 Arnecom Component Distribution Saltillo, Nuevo Leon Mexico

ARN-DC

1510 AAMSA Ascensión Ascensión, Chihuahua Mexico

AMS ASC 5116 CADYS, DC Apodaca Nuevo Leon Mexico

CadysDC

1540 AAMSA Nuevo Casas Grandes Plant 1 Nuevo Casas Grandes, Chihuahua Mexico

AMS NCG1 5160 Arnecom Cables Monterrey, Nuevo Leon Mexico

ARN-CAB

1550 AAMSA Galeana Geleana, Chihuahua Mexico

AMS GAL 5100 Arnecom Monterrey Monterrey, Nuevo Leon Mexico

ARN-MO

1560 AAMSA Constitución Constitución, Chihuahua Mexico

AMS CON 5102 Arnecom Dr. Arroyo Dr. Arroyo, Nuevo Leon Mexico

ARN-DA

1515 AAMSA Durango 1 Durango, Durango Mexico

AMS D1 5103 Arnecom Dr. Arroyo Dr. Arroyo, Nuevo Leon Mexico

ARN-DA2

1535 AAMSA Durango 2 Durango, Durango Mexico

AMS D2 5112 Arnecom Moctezuma Moctezuma, San Luis Potosi Mexico

ARN-MZ

1520 AAMSA Nuevo Ideal Nuevo Ideal, Durango Mexico

AMS NI 5114 Arnecom Valles cd. Valles, San Luis Potosi Mexico

ARN-VL

1525 AAMSA El Salto El Salto, Durango Mexico

AMS ES 5108 Arnecom Charcas Charcas, San Luis Potosi Mexico

ARN-CH







SAP Plant Code


SAP Plant Code


1530 AAMSA Canatlan Canatlan, Durango Mexico

AMS CN 5110 Arnecom Venado Venado, San Luis Potosi Mexico

ARN-V

1570 AAMSA Guadalupe Victoria Canatlan, Durango Mexico

AMS GV 5104 Arnecom Anáhuac Nuevo Leon Mexico

ARN-AN

1650 BAPSA Chih Distribution Center Buenaventura, Chihuahua Mexico

BAPSA-CDC 5106 Planta 2 Saltillo Saltillo Coahuila Mexico

ARN-SP2

1600 BAPSA Gomez Farias Gomez Farias, Chihuahua Mexico

BAPSA-GF 5121 Arnecom TuxDC Tuxtla Chiapas Mexico

Arnecom TuxDC

1610 BAPSA Madera Madera, Chihuahua Mexico

BAPSA-MD 5124 Arnecom Tuxtla Villa Flores Villaflores, Chiapas Mexico

ARN-VF

1625 BAPSA Matachic Matachic, Chihuahua Mexico

BAPSA-MT 5120 Arnecom Tuxtla Gutierrez Plant 1 Tuxtla Gutierrez Chiapas Mexico

ARN-TX1

1630 BAPSA Chihuahua Chihuahua, Chihuahua Mexico

BAPSA -CHI 5126 Arnecom Tuxtla Ocozocuautla Tuxtla Ocozocuautla, Chiapas Mexico

ARN-O

1632 BAPSA Lázaro Cárdenas Chihuahua, Chihuahua Mexico

BAPSA -LC 5134 Arnecom Tapachula Tapachula, Chiapas Mexico

ARN-TP

1640 BAPSA Ignacio Zaragoza Ignacio Zaragoza Mexico

BAPSA-IG 5122 Arnecom Tuxtla Gutierrez Plant 2 Tuxtla Gutierrez Chiapas Mexico

ARN-TX2

1660 BAPSA Flores Magon Flores Magon, Chihuahua Mexico

BAPSA-FM 5132 Plant Huixtla Tuxtla Gutierrez Chiapas Mexico

ARN-HU

1670 BAPSA Benito Juarez Flores Magon, Chihuahua Mexico

BAPSA-BJ 5173 Arnecom Nic Cadys Apodaca , Nuevo Leon Mexico

Cadys

1300 PEDSA Juarez Distribution Center Juarez, Chihuahua Mexico

PEDSA JDC 2173 Arnecom Nic el Viejo Chinandega Nicaragua NicDC

1304 PEDSA 2 Juarez, Chihuahua Mexico

PEDSA 2 2170 Arnecom Nic - Leon Plant 1 Leon, Leon Nicaragua

ARN-N1


Pedsa 3 2172 Arnecom Nic - Leon Plant 2 Leon, Leon Nicaragua

ARN-NL2


Pedsa 4 2174 Arnecom Nic - El Viejo Plant 3 El Viejo, Chinandega Nicaragua

ARN-EV

1302 PEDSA BACUM Bacum, Sonora Mexico

Pedsa BA 2176 Arnecom Nic - Leon Plant 4 Leon, Leon Nicaragua

ARN-N4







SAP Plant Code


SAP Plant Code


1302 PEDSA, Etchojoa Etchojoa, Sonora Mexico

Pedsa ET 2171 Arnecom Nic - Leon Plant 5 Leon, Leon Nicaragua

ARN-N5

1350 PEDSA Bajio Distribution Center PEDSA BDC 5178 Arnecom Nic - Cables Leon, Leon Nicaragua

ARN-NCB

1352 PEDSA Poncitlan Poncitlan, Jalisco Mexico

PEDSA PON 1850 Tecnologia Autoelectronico de Durango Durango, Durango Mexico

TAD

1354 PEDSA LEON Leon, Guanajuato Mexico

PEDSA LEON 1805 Service Manufacturing Technical Center 20 Butterfield Blvd. El Paso, TX. 79906

SMTC

1254 ACOSA, Pacific Distribution Center Obregon, Sonora Mexico

ACOSA PDC 1815 Auto Conectores de Chihuahua Plant 1 Chihuahua, Chihuahua Mexico

ACC1

1250 ACOSA Plant 1 Obregon, Sonora Mexico

ACOSA 1 1820 Auto Conectores de Chihuahua Plant 2 Chihuahua, Chihuahua Mexico

ACC2

1252 ACOSA Plant 2 Obregon, Sonora Mexico

ACOSA 2 1825 Auto Conectores de Chihuahua Plant 3 Chihuahua, Chihuahua Mexico

ACC3

1750 ACOSA EL Salvador Santana, El Salvador

ACOSA ELS 1072 COMBUE 18 Leigh Fisher El Paso, TX 79906

COMBUE

1400 SECOSA Navojoa, Sonora Mexico

SECOSA 1070 CPS 18 Leigh Fisher El Paso, TX 79906

CPS

1200 MACSA Colima Colima, Colima Mexico

MACSA

1202 MACSA TECOMAN Tecoman, Colima Mexico

MACSA TE







• The part number’s “Revision Level” (if applicable) should be printed in human readable format (not bar coded), and may be printed in its own data area to the far right of the actual part number print in the Part Number field (as shown in example A below). The Revision Level shall not be included (not scanned) in the bar code for the Part Number. It may also be printed as shown in any of the “Free Area” data areas along with the “Ship To” location as shown in examples B, C & D.

• If there is no “Revision Level” to the part number, it is not necessary to create or display a

“Revision Level” data area on the label.

• The following are examples of acceptable labels which have the “Ship To” location and “Revision Level (REV LVL)” added (yellow shaded cells for example purposes only):

\

PART NO(P) 713737 Ø 233QUANTITY(Q) 5ØØ PART DESCRIPTION


PETOSKEY, MI



WIRING TERMINALS

MFG DATE FREE AREA



REV LVL: A

SHIP TO: PEDSA 1

PART NO(P) 713737Ø 233QUANTITY(Q) 5ØØ PART DESCRIPTION

WIRING TERMINALS


PETOSKEY, MI

SUPPLIER NUMBER(V) 259212


MFG DATE

SHIP TO: PEDSA 1

CARTON WEIGHT (Kg) 13.6


REV LVL: A

PART NO(P) 713737 Ø 233QUANTITY(Q) 5ØØ


PETOSKEY, MI



MFG DATE Ø6 / Ø1 / 2ØØ9



FREE AREA

PART NO(P) 713737Ø 233QUANTITY(Q) 5ØØ PART DESCRIPTION


PETOSKEY, MI

SUPPLIER NUMBER(V) 259212


WIRING TERMINALS

REV LVL: ASHIP TO: PEDSA 1



FREE AREA

REV LVL

A

Example A Example B

Example C Example D

SHIP TO: PEDSA 1PART DESCRIPTION WIRING TERMINALS

Ø6 / Ø1 / 2ØØ9

Ø6 / Ø1 / 2ØØ9

MFG DATEØ6 / Ø1 / 2ØØ9

FREE AREA







V. PALLET CONSTRUCTION

• 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 and Non-Standardized Parts” are asked to ship product on 48” x 45” pallets.

Exceptions will be reviewed and may be given to a supplier who’s shipping volumes do

not fulfill full layers or full pallet loads on the 48” x 45” pallet, or who’s product type requires specialized packaging/dimensions.

NOTE: Suppliers who’s 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 stated in this document.

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 in Appendix D.

VI. PALLETIZATION

A. GENERAL REQUIREMENTS

• Maximum pallet load height of cartons + the pallet should be no higher than 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 and be able to stack up to 50” or less including the pallet height.

• Full level layers of cartons are required when loading pallets.

• Carton footprints should completely cube out a full layer on the pallet with NO OVERHANG.

• Barcode Labels must be both human readable and scan-able through stretch wrap or banding. Please see Appendix E for palletization standards.







B. MASTER PALLET LOAD LABEL

• 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.

• 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

C. MIXED PALLET LOAD LABEL

• 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.

• 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

D. MASTER & MIXED PALLET LABEL DESIGN

• The Master / Mixed Label shall be the same overall size as the carton (handling unit) label. The same label stock shall be used for all labels. Master / Mixed Label specification and location on pallet loads can be referenced in Appendix E







VII. SEA CONTAINER AND TRUCK TRAILER LOADING

• The purpose of this section is to provide uniform loading guidelines for sea containers and truck trailers. These guidelines should assure unit load quantities for sea containers and trailers, load configuration, methods for moisture barriers, and bracing techniques to provide load stability during transit in order to assure consistency and integrity for all incoming shipments.

A. LOAD CONFIGURATION

• All expendable cartons on wood pallets should be double stacked up to 100” high in truck trailers or High Cube sea containers (40‘ HC and 45’ HC) to fully utilize shipping trailer/container.

• All expendable cartons on slip sheets should be double stacked up to 90” high in the standard

40’ sea container to fully utilize sea container.

• All plastic returnable hand held totes on pallets and bulk bins should be double stacked if totes and triple stacked if in 34” bulk bins up to 100” high to fully utilize truck trailer.

• Stacking returnable containers on top of expendable cartons or vice versa is prohibited.

Stack lighter unit loads on top of heavier unit loads.

Hand held carton unit loads should be loaded toward the front of the shipping

trailer/container.

Partial unit loads should be loaded toward the rear of the container or trailer.

Weight must be evenly distributed side to side and end to end of the container or trailer.

B. LOADING REQUIREMENTS

• It is the Component Supplier’s and/or Shipping Company’s responsibility to assure that the most effectively utilized truck trailer or sea container is selected when shipping product, depending on the unit load size.

• If loading patterns in this guideline cannot be followed by the Component Supplier and/or

Shipping Company, they should notify Yazaki Packaging, Transportation, and Production Control immediately for approval to ship. Bracing diagrams are located in Appendix F

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IX. SUPPLIER TEST SHIPMENTS

A. TEST SHIPMENT CRITERIA

1) Reasons for Test Shipments

• New Component Supplier

• Change of Part, Packaging, or Shipping Method

• New Part

• As Deemed Necessary

Each test shipment shall be coordinated with Yazaki Component Packaging Specialist.

Each test shipment shall be labeled on all 4 sides of the pallet load with large, brightly colored Yellow labels. Specific trial information required on labels will be provided by Yazaki Component Packaging Specialist.

X. SHIPMENT DAMAGE

A. DAMAGE DOCUMENTATION & RESOLUTION

• Yazaki Component 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 Supplier’s 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:

GQRS reports and/or charge backs for damaged packaging & product may be issued to

the Component Supplier.

Component Supplier Rating may be affected.







XI. PACKAGING QUESTIONS & ISSUES

• Packaging issues may be communicated to Yazaki Component Packaging Specialist by contacting:

Nathan Laming: [email protected]

Nick Scott: [email protected]







Edge Crush Test (lbs/inch)

Corrugated Board Material

Burst Strength (psi)

32 ECT Single Wall (SW) 200#40 ECT Single Wall (SW) 250#44 ECT Single Wall (SW) 275#55 ECT Single Wall (SW) 350#

42 ECT Double Wall (DW) 200#48 ECT Double Wall (DW) 275#51 ECT Double Wall (DW) 350#61 ECT Double Wall (DW) 400# Elevated Strength Double Wall

Remarks

Do Not Use / Not AllowedMin. Double Wall RequirementElevated Strength Double Wall

Min. Single Wall RequirementElevated Strength Single Wall

Do Not Use / Not AllowedDo Not Use / Not Allowed

XII. APPENDIX A

A. PREFERRED CARTON DIMENSIONS AND SPECIFICATIONS • The table represents the preferred carton footprint, heights, and minimum carton material strengths

for component packaging systems: 1. 2. 3. 4.

Carton Dimensions

• Single Wall cartons shall be constructed of C-Flute linerboard. Double Wall cartons shall be

constructed of B-C Flute linerboard. All export shipments overseas and through air are REQUIRED to have double wall corrugate boxes.

1 2 3 4 5 612 x 11 x 5 16 ok ok ok ok ok ok 16 96 1 1 1 1 1 1 2 2 2 2 2 2 2 212 x 11 x 7 16 ok ok ok ok ok ok 16 96 1 1 1 1 1 1 2 2 2 2 2 2 2 212 x 11 x 9 16 ok ok ok ok ok 16 80 1 1 1 1 1 1 2 2 2 2 2 2 2 215 x 12 x 5 12 ok ok ok ok ok ok 12 72 1 1 1 1 2 2 2 2 2 2 2 2 2 215 x 12 x 7 12 ok ok ok ok ok ok 12 72 1 1 1 1 2 2 2 2 2 2 2 2 2 215 x 12 x 9 12 ok ok ok ok ok 12 60 1 1 1 1 2 2 2 2 2 2 2 2 2 215 x 12 x 11 12 ok ok ok ok 12 48 1 1 1 1 2 2 2 2 2 2 2 2 2 224 x 11 x 7 8 ok ok ok ok ok ok 8 48 1 1 1 1 2 2 2 2 2 2 2 2 2 224 x 11 x 9 8 ok ok ok ok ok 8 40 1 1 1 1 2 2 2 2 2 2 2 2 2 224 x 11 x 11 8 ok ok ok ok 8 32 1 1 1 1 2 2 2 2 2 2 2 2 2 224 x 15 x 7 6 ok ok ok ok ok ok 6 36 1 1 2 2 2 2 2 2 3 3 3 3 3 324 x 15 x 9 6 ok ok ok ok ok 6 30 1 1 2 2 2 2 2 2 3 3 3 3 3 324 x 15 x 11 6 ok ok ok ok 6 24 1 1 2 2 2 2 2 2 3 3 3 3 3 324 x 22.5 x 7 4 ok ok ok ok ok ok 4 24 2 2 2 2 2 2 3 3 3 3 3 3 3 324 x 22.5 x 9 4 ok ok ok ok ok 4 20 2 2 2 2 2 2 3 3 3 3 3 3 3 324 x 22.5 x 11 4 ok ok ok ok 4 16 2 2 2 2 2 2 3 3 3 3 3 3 3 3

48 x 15 x 7 3 ok ok ok ok ok ok 3 18 3 3 3 3 3 3 3 3 4 4 4 4 4 448 x 15 x 10 3 ok ok ok ok 3 12 3 3 3 3 3 3 3 3 4 4 4 4 4 448 x 15 x 15 3 ok ok ok 3 9 3 3 3 3 3 3 3 3 4 4 4 4 4 448 x 22 x 10 2 ok ok ok ok 2 8 3 3 3 3 4 4 4 4 4 4 4 4 4 448 x 22 x 15 2 ok ok ok 2 6 3 3 3 3 4 4 4 4 4 4 4 4 4 448 x 22 x 22 2 ok ok 2 4 3 3 3 3 4 4 4 4 4 4 4 4 4 4

48x45 Wooden Pallet +0/-0.5" Ctns / Pallet

Carton Size (OD) +0/-0.5" Ctns / LayerAllowable # Layers

Min

Max

Ctn Weight (lbs) w/Product: M inimum Carton M aterial ECT0 - 5 5 - 10 10 - 15 15 - 20 20 - 25 25 - 30 30 - 35

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Horizontally palletized spools are NOT allowed.

B. SPECIAL PACKAGING SYSTEMS

1) WIRE SPOOLS / NPS’

• Horizontal palletizing of wire spools is NOT ALLOWED. Overlapping of spools on pallet is NOT ALLOWED.

• Large spools (Type A & B as shown below) which do not take up the full footprint of the pallet must be banded to the pallet in a 4-way pattern. Banding material should be steel. Smaller spools (Types C, D, and E as shown below) which take up the full footprint of the pallet may also be banded, but should always be stretch wrapped as shown, with “X” pattern on top for final wrap. All 4 corners of pallet should be included in the stretch wrap.

Overlapping of spools is NOT

allowed.

Palletized Spool Type "A" Palletized Spools Type "B" Palletized Spools Type "C" Palletized Spools Type "D" Palletized Spools Type "E"

S

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W

RSC -REGULAR SLOTTED

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1/2 W

1/2 W

W

FFSC - FULL FLAP SLOTTED

CONTAINER

W

W

3) TERMINAL REEL CARTONS

• ALL terminal cartons shall be a minimum of 44 ECT Single Wall Corrugate.

• Carton dimensions shall be such that they do not overhang the pallet in any location when layered on the pallet.

• Terminal Reels may be packed in several allowable carton styles:

RSC (Regular Slotted Carton): The constructed RSC carton has outer flaps that meet at the center, on both top and bottom surfaces.

FFSC (Full Flap Slotted Carton): The FFSC, unlike the RSC, has outer flaps that fully overlap. This offers extra strength and support to the carton. This style is especially suited to cartons that have a very narrow width (i.e., Terminal Reel Cartons).







Yazaki’s Preferred Terminal Carton Design is a Rollover Carton w/Hinged Lid.

4) CONVOLUTE TUBING

• Bulk Convolute Tubing carton may be packed in Octagonal style Gaylord.

• Minimum board strength shall be 275 Lb. Double Wall Corrugate. Stronger cardboard material may be used.

• Pallet dimension should be fit to the size of the carton so that the carton does not overhang the

pallet in any location.

• Carton(s) shall be secured to pallet with minimum of two banding straps as shown below. An additional banding strap in the cross dimension is recommended.

ROLLOVER CARTON W /

INTEGRATED CORNER POSTS







OK for use inside of carton OK for external pallet load

bracing / stability

1

2 3

4

RSC CARTON

3/4" Masking TapeMinimum of 3 Tapes

per Corner Post

XIII. APPENDIX B

A. DUNNAGE OPTIONS

1) 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 Corrugate) may be used

inside of any carton to provide additional stacking strength.

• If used internally, corner posts should be installed using ¾” wide masking tape as shown in diagram below. Use a minimum of three spot tapes to secure each corner post.







• Laminated L-Shaped posts are not preferred inside of cartons but may be used externally on pallet loads to provide stability if necessary.

XIV. APPENDIX C

A. BAR CODE SYMBOLOGY

• The bar code labels shall follow the bar code standard set by AIAG Shipping/ Parts Identification label guideline B-3.

1) Code Configuration

• The four symbols ($, /, +, %) of the Code 39 Symbology shall not be used on the bar code label.

2) Code Density and Dimension

• All Bar Code heights shall be 0.5 inch (13mm). For each bar code symbol, the average width of the narrow elements shall be within the range of 0.013 to 0.017 inch (0.33-0.43mm). The ratio of the average width of the wide elements of the average width of the narrow elements shall be 3:1, with an allowable range of 2.8:1 to 3.2:1. The leading and trailing edge “quiet zone” should be at least 0.25 inch (6.4mm). Inter-character gap width should be the same as the width of the average narrow elements, plus or minus the element width tolerance.

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.







3) Reflectivity and Contrast

• Reflectivity and contrast shall be measured at B900 nanometers. Symbol shall comply with all optical specifications of AIAG B-1.

• Resolution (minimum width) of bar code lines must be at least 10 mils (0.010”).

B. DATA AREAS AND TITLES

• Data areas should be separated by thin horizontal lines and should contain their respective titles in the upper left hand corner. Preferably, thin vertical lines should be used to separate all data areas.

• Titles should be printed in 0.1 inch (2.5mm) high letters.

• Human readable information is recommended to show any Zeroes (Ø) with a slash mark (/)

through the zero to differentiate from alphabetical letter O’s. • ALL text, bar codes, and data area lines shall be printed in black.

1) Data Identifiers

• Data identifiers shall be used as defined in the current ANSI FACT-1 Data Identifier Directory Standard. A data identifier immediately follows the start character of the bar code symbol and is used to identify the information to follow. More discussed below.

2) Part Number Area (P) – (Required: Bar Code and Human Readable Format)

• Human readable part number characters shall be bold and a minimum of 0.5 inch (13mm) high.

• The bar code symbol shall be directly below the human readable characters, and shall be a minimum of 0.5 inch (13mm) high and shall contain the data identifier (P) in the actual scan.

Dashes and spaces should NOT be included in the bar coded form of the part number or in the human readable of the part number.

• The actual Part Number printed in human readable format and bar coded format shall be the

YAZAKI part number as it appears in the release.

3) Quantity Area (Q) – (Required: Bar Code and Human Readable Format)

• Human readable quantity characters shall be bold and a minimum of 0.5 inch (13mm) high.







• The bar code symbol for the quantity shall be directly below the human readable characters, and shall be a 0.5 inch (13mm) high and shall contain the data identifier (Q) in the actual scan.

• Quantity shall be the total number of pieces contained in one Handling Unit.

4) Supplier Number Area (V) – (Optional: Bar Code and Human Readable Format)

• Human readable supplier number characters shall be a minimum of 0.2 inch (5mm) high.

• The bar code symbol for the supplier number shall be directly below the human readable

characters, and shall be a 0.5 inch (13mm) high and shall contain the data identifier (V) in the actual scan.

• The Supplier Number shall be the 7 digit SAP Supplier Account Number assigned to the

Component Supplier. It is the supplier’s discretion whether or not they wish to fill in the Supplier Number Data Area.

5) Serial Number Area (S) – (Required: Bar Code and Human Readable Format)

• The human readable serial number characters shall be a minimum of 0.2 inch (5mm) high.

• The bar code symbol for the serial number shall be directly below the human readable characters, shall be a minimum of 0.5 inch (13mm) high, and shall contain the data identifier (S) in the actual scan.

• A unique 16 to 18 digit numeric or alpha-numeric serial number will be generated and tracked

by the component supplier for each handling unit of product shipped to Yazaki. A serial number shall never be repeated.

• All component suppliers are responsible for generating serial numbers that are unique across all

of their part numbers.

• Each component supplier’s specific (up to 7 digit) numeric SAP Supplier Account Number shall be the prefix/beginning of every serial number. SAP Supplier Account Numbers will be communicated through YAZAKI core purchasing group to all vendors. This 7 digit numeric SAP Supplier Account Number must be specified in the first 7 positions of every serial number for every part number & handling unit label.







6) Part Description – (Required: Human Readable Format)


• Description should be printed in 0.1 inch (2.5mm) high letters.

• Part Description may be full descriptive wording or abbreviation.

7) Carton Weight – (Required: Human Readable Format)


• Weight should be printed in 0.1 inch (2.5mm) high numbers.

• Shall be shown in the unit of Kgs. to 0.1 accuracy, and is the total weight (carton plus product and any internal packaging dunnage such as cells, dividers, bags, etc.).

8) MFG Date – (Required: Human Readable Format)


• Date should be printed in 0.1 inch (2.5mm) high numbers.

• Shall be shown in mm/dd/yyyy format.

9) Free Area – (Required: Ship To / Rev LVL)

• This area may be used by the component supplier for Ship To Code and Rev LVL (if available).

• Title should be printed in 0.1 inch (2.5mm) high letters.

• Data should be printed in 0.1 inch (2.5mm) high letters or numbers.

10) Supplier PN (2P) – (Optional, bar code and human readable format is preferred)

• The Supplier PN (2P) Area shall contain the component supplier’s part number and is for the

component supplier’s purposes. Bar coding this area is optional for the component supplier.








• Supplier PN should be printed in 0.2 inch (5.0mm) high numbers.

• Bar code (if used) should be printed to 0.5 inch (16mm) tall.

• The bar code symbol shall be directly below the human readable characters, and shall be a

minimum of 0.5 inch (13mm) high and shall contain the data identifier (2P) in the actual scan if this area is to be scanned. This ensures incorrect scans will not occur at Yazaki locations between the Yazaki Part Number (P) and the Supplier Part Number (2P).

11) Assembled In / Country of Origin & Component Supplier Name (Required: Human Readable)

• The “Assembled In” or “Country of Origin” location shall be printed at the top of this area.

• The name of the Component Supplier shall be printed following the “Assembled In/Country of

Origin” location.

• There is no required font size or style but the printing must be large enough to be human readable.

XV. APPENDIX D

A. PALLET CONSTRUCTION

• Preferred pallet footprint with tolerances shall be 48” x 45”

Stringers Deck Boards 48” (+0” / -1/4”) x 45” (+0” / -1/4”)

• Pallets must provide a 4-way fork entry and be of double face non-reversible wood

construction.

• 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."







• The preferred Yazaki pallet footprint is shown below.

• The combined surface area of deck boards must be equal to or greater than 50% of the actual

surface area of the pallet footprint. Larger surface coverage is preferred.







XVI. APPENDIX E

A. PALLETIZATION LABEL PLACEMENT

• Each carton shall be labeled with 2 labels on adjacent corners as shown below. When loaded on a pallet at least 1 label must be visible on each box at all times.

B. 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 Overseas). 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.

OK: 2 Labels per Carton on adjacent

sides of carton

NO GOOD: Labels are on opposite sides of

cartonOK!

OK!

NO GOOD!

NO GOOD!

No Overhang allowed!







NOT OK

NOT OKOK

OK

Cardboard Layer Pad

• At least 2 opposite edges of carton MUST be completely supported by the top deck boards of pallet so that all 4 corners of the carton rest upon the deck boards.

• If carton sizes selected are not sufficiently supported on two opposite edges by the deck boards

of the pallet, a single layer of 48” x 45” corrugate that is no larger than the pallet shall be used between the pallet and the bottom layer of cartons.

• 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.

NOT OK: "Bricklayering" or Interlocking patterns are not allowed

OK: Cartons are aligned vertically

S

GUIDELINE/S

AA‐SC



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2016‐MAR


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A

A

A

A

A

A

A

A

A

A

A

A

Pallet Load #2,Order 1

B B

B

B

B

B B

B B


B B

B B

B BA

C

C

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F

F

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E

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F

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D E F

E E

D E

E E

D E

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F

F F

F F

F F

F F

F F

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D D

D

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F

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A

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C C

C C

C C

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Back Column, 3 boxes, hiddenBack Column, 3 boxes, hidden


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.

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:







D. MASTER / MIXED LABEL REQUIREMENTS

• The Master Pallet and Mixed Pallet bar code shall be a minimum of 1 inch tall (25.4 mm). The Master label shall contain the data identifier (4S), and the Mixed label shall contain the data identifier (5S).

MASTER PALLET LABEL EXAMPLE

MIXED PALLET LABEL EXAMPLE

6.0" - 7.0"

4.5" - 5.5"SERIAL NO. (4S) 1234567ABCDEFGHIJ

MASTER PALLET

1" (25.4mm)

NOTE: ALL text and bar codes should be printed in black.

1" (25.4mm)

6.0" - 7.0"

4.5" - 5.5" SERIAL NO. (5S) 1234567ABCDEFGHIJ

MIXED PALLET

1" (25.4mm)

NOTE: ALL text and bar codes should be printed in black.

1" (25.4mm)







E. MASTER & MIXED PALLET LOAD LABEL LOCATIONS

• There shall be a minimum of 1 Master or Mixed labels for each pallet shipped. 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.

• 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.

• Master Load Labels and Mixed Load Labels shall be placed so that they do not cover any of the

carton’s barcode (handling unit) labels as per below.

A.

A

A

B

A

A

B

M

MMaster 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)

M

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







Entire top edge of cartons covered with stretch wrap

Stretch wrap includes all 4

corners of pallet

Stretch Wrap overlaps minimum

of 40% per wrap

F. 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.

S

GUIDELINE/S

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6” Space or More, Use Bracing

XVII. APPENDIX F

A. BRACING

• Unit Load Shipments require a bracing technique (ISPM Compliant wood or tension bar) when there is 6” or more of excess space at the rear of the container or trailer. If there is more than 12” between 2 unit loads in any direction sideways, airbags should be used as shown below. Yazaki recommends using one or more of the following bracing methods:

12” Gap or more: use air pillows

Light unit loads are placed on top of

heavier unit loads

Hand Held Cartons are placed towards the front

of the container

S

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B

GUIDELINE/S

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C. AIR BAGS

• When used, it is preferred that Air Bags should be clear/see-through when possible to aid Customs when inspecting.

• Return system for reuse and prevent loss must be established.

• Should be approved between Supplier and Yazaki before implementation.

• Air Bags should be used between pallet loads that have more than 12” between them so that the

air bag pushes the pallet loads against the sea container/truck trailer wall.

D. WOODEN BRACING

• Wood must meet ISPM 15 Requirements for fumigation or heat treatment.

• Size of lumber (i.e. 2”x4” or 2”x6”) must be appropriate for the weight of unit loads.

• Lumber must be cut to length and wedged into corrugation of walls of sea container/truck trailer.

• Lumber may be nailed to floor, but it is not recommended.







XVIII. DOCUMENT HISTORY

These authorities are responsible for the content and authorize its release and usage by Yazaki North and Central America (YNCA).

Name Title Department Rev. Level Date Process Engineer (Prepared by):

Nathan Laming Comp. PKG Specialist SCM ‐ Logistics New 2016‐MAR‐30

Renee Roberts Project Manager SCM – Tools & Processes New 2016‐MAR‐30Process Owner (Checked by):

Nick Scott Manager SCM ‐ Logistics New 2016‐MAR‐24

Management (Approved by):

Nick Scott Manager SCM ‐ Logistics New 2016‐MAR‐24

Eric Lindstrom Director SCM – Logistics New 2016‐MAR‐31

*For Yazaki operational definitions and usages, please consult YNCA Operational Governance from the main YNA Connection page.

Revision Details (only keep the latest three major revisions) Rev. Level Initial Release 1.0

component supplier packaging and shipping guideline

Documents