Yazaki North America, Inc.

, 6801 Haggerty Road, Canton, MI 48187

734-983-1000

1 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guideline for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

Component Supplier Packaging Guideline for Standard Parts

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

2 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

TABLE OF CONTENTS
1.0 2.0 SCOPE ALLOWABLE CARTON DIMENSIONS
2.1 2.2 2.3 Allowable Dimensions & Minimum Board Strengths Bulk Cartons Cartons Loading Diagrams

pg. 2 pg. 3 pg. 4

pgs. 4, 5 pg. 6 pg. 6

3.0

GENERAL CARTON CONSTRUCTION REQUIREMENTS pg. 7

3.1 3.2 Design Carton Corner Posts pgs. 7, 8 pgs. 9, 10

4.0 5.0

CARTON UTILIZATION REQUIREMENT PALLET CONSTRUCTION

5.1 5.2 Pallet Dimensions Materials & Construction

pg. 10 pg. 12
pg. 12 pgs. 12-14

6.0

PALLETIZATION
6.1 6.2 6.3 6.4 General Requirements Stretch Wrap Banding Palletization of Cartons on Pallet

pg. 14
pg. 14 pg. 14 pg. 15 pgs. 15, 16

7.0 8.0 9.0

SUPPLIER TEST SHIPMENTS

7.1 Test Shipment Reasons

pg. 17
pg. 17

SHIPMENT DAMAGE
8.1 Damage Documentation and Resolution

pg. 17
pg. 17

LABELING
9.1 9.2 9.3 Carton Labeling Mixed Pallet Loads Master & Mixed Loads: General Info

pg.18
pg.18 pgs. 18-21 pg. 22,23

10.0 ENVIRONMENTAL POLICY AND SOCS 11.0 PACKAGING QUESTIONS & ISSUES

pg. 24 pg. 24

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

3 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

1.0

SCOPE
The Yazaki Component Supplier Packaging Guideline for Standard Parts outlines the minimum requirements for packaging systems of the following component families: o o o o o o o Tape / Foam Clips / Fasteners Nuts / Bolts / Screws Connectors Relays Grommets Some Shields & Brackets

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. These minimum requirements shall be met by all component suppliers shipping standard parts to Yazaki North America. (Non-Standard part packaging requirements are discussed in Yazakis Component Supplier Packaging Guideline for Non-Standard Parts.) The packaging systems contained within this document will be used primarily in sea containers (40, 40 High Cube, and 45) and shipped overseas to Yazaki manufacturing locations throughout the world. 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 Suppliers 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.

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

4 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

2.0

ALLOWABLE CARTON DIMENSIONS

2.1 ALLOWABLE DIMENSIONS & MINIMUM BOARD STRENGTHS The table represents the allowable carton footprint, heights, and minimum carton material strengths that are allowed for the various component families:
Edge Crush Test (lbs/inch) 32 ECT 40 ECT 44 ECT 55 ECT 42 ECT 48 ECT 51 ECT 61 ECT Corrugated Board Material
Single Wall (SW) Single Wall (SW) Single Wall (SW) Single Wall (SW) Double Wall (DW) Double Wall (DW) Double Wall (DW)

Burst Strength (psi) 200# 250# 275# 350# 200# 275# 350# 400#

Remarks Do Not Use / Not Allowed Do Not Use / Not Allowed Min. Single Wall Requirement Elevated Strength Single Wall Do Not Use / Not Allowed Min. Double Wall Requirement Elevated Strength Double Wall Elevated Strength Double Wall

Double Wall (DW)

CARTON SI ZES & MI NI MUM CARDBOARD MATERI AL REQUI REMENT

STANDARD I TEMS Nuts / Bolts / Screws STANDARD & NON-STANDARD I TEMS Plastic Connectors Rubber Grommets (Std. & Non Std.) Shields / Brackets (Std. & Non Std.) Relays & Busbars NON-STANDARD I TEMS

Convolute Tubing

Adhesive Tape / Foam Tape

Terminal Reels
SW

(L)
48 x 45 Wooden Pallet (+ 0 / - 0.5")
11 1/4 x x x x x x x x x x x x x x x

(W)
6 11 1/4 11 1/4 12 12 11 1/4 22 1/2 22 1/2 15 15 22 1/2 22 1/2 22 1/2 45 45 x x x x x x x x x x x x x x x

(H)
5 5 10 5 10 10 10 15 10 15 10 15 20 ? ?

Hand-Held

12 12 22 1/2 22 1/2 24 24 24 48 48 48 48 48 ? 45

Standard Packaging

SW SW SW SW SW SW

SW SW SW

DW DW DW

SW SW SW SW SW SW SW SW

SW SW SW SW SW SW SW SW

Non Standard Packaging

SW SW SW SW SW SW DW DW DW DW DW DW DW DW

SW SW SW SW SW SW DW DW DW DW DW DW DW X

Bulk

24 1/2 x 24 1/2 x ? CARTON NOT APPLI CABLE

Wire Spools / Liquid Jugs

Carton Size - OD (Outer Dimensions) + 0 / -0.5" (in inches)

Metal and Plastic Clips & Fasteneers

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

5 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

Single Wall cartons shall be constructed of C-Flute linerboard. Double Wall cartons shall be constructed of B-C Flute linerboard.
SINGLE WALL CARTON BOARD FLUTE REQUIREMENT (C-FLUTE) DOUBLE WALL CARTON BOARD FLUTE REQUIREMENT (B-C FLUTE)

There are no exceptions to these minimum requirements. Cardboard strengths less than the stated rating and flute are not sufficiently strong enough to withstand overseas shipments and possible multiple handlings by the freight carriers. Yazaki Packaging Engineering will contact the Component Supplier directly and work with them when packaging damage is chronic. Certain product families and cartons sizes may require stronger board strengths when the required minimum board strength is found to be insufficient. Carton heights other than 5, 10, 15 or 20 are NOT allowed. o Yazakis reasoning for requiring standardized heights of all incoming packaging is because mixed pallet loads for outbound shipments must be built from numerous component suppliers products/packaging. A Component Suppliers own pallet load of parts is frequently dismantled, and new pallet loads are reassembled with various other cartons from other Component Suppliers to meet order requirements for Yazakis manufacturing locations. Standardized carton heights make it easier to assemble mixed pallet loads and keep carton layering level on the mixed pallet loads.

The Ergonomic Weight Limit for Hand-Held cartons is 30 Lbs (weight of empty carton, interior dunnage, & product combined).

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

6 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

2.2

BULK (LARGE/LONG) CARTONS Certain Standardized Parts, such as long plastic shields, may require using longer carton footprints in order to fit the part correctly. Yazaki allows the use of 48 x 22 and 48 x 15 carton footprints with the specified heights shown in the table in Section 2.1. If the part is longer than 48, carton footprints should be sized so that the 45 side of the pallet is maintained so that an X x 45 pallet can be loaded 2 across in a sea container (i.e., carton widths of 11 , 15, 22 with carton lengths as long as required for the part to fit). Allowable Bulk Carton heights are 10, 15, and 20 (+/- 0.25). CARTON LOADING DIAGRAMS The diagram below details the layering method on the pallet for the required carton footprints on the 48 x 45 pallet:

2.3

HAND HELD CARTONS

11 1/4" x 6"
6x 11.25 6x 6x 11.25 11.25 6x 11.25 6x 11.25 6x 6x 11.25 11.25 6x 11.25 12 x 11.25

12" x 11 1/4"
12 x 11.25 12 x 11.25 12 x 11.25 12 x 22.5

22 1/2" x 12"

24" x 11 1/4"
24 x 11.25 24 x 11.25

24" x 22 1/2"

12 x 22.5

12 x 22.5

12 x 22.5 24 x 11.25 24 x 11.25

24 x 22.5

24 x 22.5

6x 11.25

6x 6x 11.25 11.25

6x 11.25

6x 11.25

6x 6x 11.25 11.25

6x 11.25

12 x 11.25

12 x 11.25

12 x 11.25

12 x 11.25

45"
6x 11.25 6x 6x 11.25 11.25 6x 11.25 6x 11.25 6x 6x 11.25 11.25 6x 11.25 12 x 11.25 12 x 11.25 12 x 11.25 12 x 11.25 12 x 22.5 6x 11.25 6x 6x 11.25 11.25 6x 11.25 6x 11.25 6x 6x 11.25 11.25 6x 11.25 12 x 11.25 12 x 11.25 12 x 11.25 12 x 11.25 12 x 22.5 12 x 22.5 12 x 22.5 24 x 11.25 24 x 11.25 24 x 11.25 24 x 11.25 24 x 22.5 24 x 22.5

48"

BULK CARTONS
48" x 22 1/2" 48" x 15"
48 x 15 48 x 22.50

48 x 15

48 x 22.50 48 x 15

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

7 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

3.0

GENERAL CARTON CONSTRUCTION REQUIREMENTS

3.1 DESIGN All cartons (Hand-Held & Bulk) shall be RSC (Regular Slotted Containers) with flaps for closure. HSC Style Cartons (removable lid) are not allowed. Hand holes should NOT be used, unless specified by YNA Packaging Engineering. If hand holes are required, YNA Packaging will notify the component supplier of the hand hole requirement. Corrugated cartons shall be designed to withstand 90% humidity at 30F - 150F 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:
GUA RA MAKER N OX CER TIFICATE TE E X IN BO G THIS DOUBLEWALL BOX MEETS ALL CONSTRUCTION REQUIREMENTS OF APPLICABLE FREIGHT CLASSIFICATION

OF

BOX

AM

BURSTING TEST MIN COMB WT FACINGS SIZE LIMIT GROSS WT LT

LBS PER SQ INCH LBS PER M SQ FT INCHES LBS

CI

TY A

ND

ERE STATE IN H

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

8 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

The manufacturers joint for carton seam closure is preferred to be glued. Staples are acceptable as long as no part of any staple is protruding out from the carton material (staples create possible snag points for parts and injury concerns). o If stapling the manufacturers joint, metal staples should be no less than 0.103 wide and 0.023" thick.
Manufacturer's Joint (Glue Preferred, Staples allowed)

Cartons should be closed with tape at every location flaps meet with each other and with the main carton body. At least 6 tape locations shall be used per RSC carton.
6 5 4

3 2 1

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

9 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

3.2

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 Cardboard) may be used inside of any carton to provide additional stacking strength.

OK for use inside of carton

OK for external pallet load bracing / stability

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

2 3/4" Masking Tape Minimum of 3 Tapes per Corner Post 1 RSC CARTON

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

10 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

Laminated L-Shaped posts are not preferred inside of cartons because they do not provide adequate support due to lack of surface area, but may be used externally on pallet loads to provide stability if necessary.

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.

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

11 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

4.0

CARTON UTILIZATION REQUIREMENT

Yazaki North America is heavily focused on the maximum utilization of all shipping containers, starting with the primary pack (carton) through the final conveyance (trucking trailer & sea container). Cartons that are under filled are both costly to transport, and also increase the chance of damage to the overall packaging system and the parts contained. Therefore, Yazaki is imposing a Minimum Carton Utilization Requirement for all components. Suppliers will be notified if they ship parts which do not meet this minimum utilization requirement. Supplier should select the carton footprint and height which best fits the Vertical Carton Utilization and Product to Carton Footprint Utilization Requirements: Vertical Carton Utilization is defined as: Product Fill Height / Carton Height o Minimum Vertical Carton Utilization shall be at least 90%. Product to Carton Footprint Utilization is defined as: L x W of Product Fill / L x W dimensions of Carton o Product to Carton Footprint Utilization shall be a minimum of 80% in a fully packed carton.
EXAMPLE: CARTON SHOWN PACKED WITH LOOSE PRODUCT Product to Carton Footprint Utilization Requirement: 80% of L x W of Carton
10%

80% (H)eight

Vertical Carton Utilization Requirement: 90% the Height of Carton

90%

(W)idth (L)ength

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

12 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

5.0

PALLET CONSTRUCTION
5.1 PALLET DIMENSIONS 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 Parts are required to ship product on 48 x 45 pallets. o Exceptions will be reviewed and may be given to a supplier whos shipping volumes do not fulfill full layers or full pallet loads on the 48 x 45 pallet, or whos product type requires specialized packaging/dimensions. o NOTE: Suppliers whos 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 previously stated in this document. 5.2 MATERIALS & CONSTRUCTION Required pallet footprint with tolerances shall be 48 x 45 Stringers 48 (+0 / -1/4) Deck Boards 45 (+0 / -1/4)

Pallets must provide a 4-way fork entry and be of double face non-reversible wood construction. Pallets other than wood construction are to be reviewed and approved by YazakiPackaging Eng. Dept. 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." Do not use pallets with rotted or decayed lumber, knots/knotholes, bark, or splintered wood. Check for splits that will affect holding strength or interfere with nailing.

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

13 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

All nails should be flush to surface of wood or recessed slightly. Recycled pallets which are not sound or that are not within the tolerances (+ 0 / - 0.25) of the required pallet footprint of 48 x 45 are not allowed. Do not use wooden pallets which show signs of insect infestation. Pallet quality is the foundation for ensuring overall packaging system quality and minimizing packaging system failures. o 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. o The required Yazaki pallet footprint is shown below.

The combined surface area of deckboards must be equal to or greater than 50% of the actual surface area of the pallet footprint. In example above, deckboard widths are 4, 4, 8, 4, & 4 = 24. Length of pallet is 48. 24 x 45 / 48 x 45 = 50% surface coverage and is technically acceptable. Larger surface coverage is preferred. This

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

14 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

requirement provides adequate support for the bottom layer of cartons so that they do not drop between the deckboards and cause failure/crushing of the entire pallet load or allow spearing of the undersides of cartons by hi-lo forks.

6.0

PALLETIZATION
6.1 GENERAL REQUIREMENTS Maximum pallet load height of cartons + the pallet should be no higher than 50. As previously stated, allowable hand-held carton heights are 5, 10, and 15. Allowable Bulk carton heights are 10, 15, and 20. These heights are required to make an overall pallet load height of 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. Carton footprints should completely cube out a full layer on the pallet with no overhang. 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.
Entire top edge of cartons covered with stretch wrap Stretch Wrap overlaps minimum of 40% per wrap

6.2

Stretch wrap includes all 4 corners of pallet

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

15 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

6.3

BANDING If banding is used, the banding (minimum 0.5 wide x 0.021 thick) must be extruded Nylon Polypropylene, or made of pre-elongated (oriented) material and able to contract upon itself the extent of its stretch created upon application. Steel banding is NOT ALLOWED for Standard Item Components. A minimum of 4 banding straps should be used (2 for length, 2 for width direction of pallet). Additional banding straps (5 or more) should be used if the cartons being palletized are not in a 2 x 2 layer arrangement on the pallet in order to secure each column of cartons on the pallet. Fusing straps or crimp seals should be used to secure banding. Use of buckles is not acceptable unless approved by Yazaki Packaging Engineering Dept.

6.4

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 Asia). All container systems shall have sufficient structural integrity to support normal handling and storage. 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. Overhanging cartons destroy the vertical stacking strength of the entire pallet load and facilitate crushing of the cartons. Overhanging Cartons can lose up to 50% of their vertical stacking strength.

No Overhang allowed!

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

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YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

At least 2 opposite edges of carton MUST be completely supported by the top deckboards of pallet so that all 4 corners of the carton rest upon the deckboards. Any carton that is floating or suspended with less than two edges of the carton fully supported by the deckboards creates the risk of dropping through the deckboards and causing the unit load to fail. Cartons gain the majority of their stacking strength from their corners. If carton sizes selected are not sufficiently supported on two opposite edges by the deckboards of the pallet, a single layer of 48 x 45 cardboard that is no larger than the pallet shall be used between the pallet and the bottom layer of cartons to ensure an even layer and that the cartons do not drop between the deckboards.

OK

NOT OK
Cardboard Layer Pad

OK

NOT OK

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.

OK: Cartons are aligned vertically

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

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

17 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

7.0

SUPPLIER TEST SHIPMENTS

7.1 A TEST SHIPMENT MAY BE REQUIRED FOR THE FOLLOWING REASONS: New Component Supplier. Change of Part, Packaging, or Shipping Method. New Part. As deemed necessary. o Each test shipment shall be coordinated with Yazaki Packaging Engineering. o 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 Packaging Engineering.

8.0

SHIPMENT DAMAGE
8.1 DAMAGE DOCUMENTATION & RESOLUTION Yazaki Components 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 Suppliers 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: o GQRS reports and/or charge backs for damaged packaging & product may be issued to the Component Supplier. o Component Supplier Rating may be affected.

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

18 of 24
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YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

9.0

LABELING
9.1 CARTON LABELING Each carton shall be labeled with 2 labels on adjacent corners as shown below:
NO GOOD: Labels are on opposite sides of carton OK! NO GOOD!

OK: 2 Labels per Carton on adjacent sides of carton

OK!

NO GOOD!

Refer to YAOM-PE-S12-014W YNA Component Supplier Carton Barcode Label Guideline for specific carton barcode labeling format and design requirements.

9.2

MIXED PALLET LOADS: ALLOWABLE SITUATIONS & LABELING Mixed Loads (pallets with multiple part numbers): o Are allowed if the Yazaki order of one part number is not enough to complete a full pallet load of that part number. o Are allowed if the Cartons used to ship product to Yazaki are very small in nature and do not take up a complete layer on the pallet. o The same part number from the same order # should be kept on the same pallet to create a full pallet load of that part number. Leftover cartons from this part number which do not complete the next full pallet load may be used to make a Mixed Pallet Load with additional leftover cartons/part numbers.

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

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YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

The following methodology shall be followed by the component supplier when palletizing orders for a Yazaki Distribution Center: o Final Mixed Load Pallets with multiple part numbers shall be packed so that the same part numbers are grouped together on the pallet as shown below: MIXED PALLET LOAD

Back Column, 3 boxes, hidden

Back Column, 3 boxes, hidden

B A A B C

C B C C B

OK! Same part levels are stacked together.

NO GOOD! Part numbers are not stacked together. Same part levels are all over in pallet.

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

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2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

o Pallet loads from the same order should be packed completely with the same part number completing as much of a pallet as possible before adding more part numbers. Final pallet(s) should be mixed pallet as shown by Pallet Load #2.
Pallet Load #1
Back Column, 3 boxes, hidden Back Column, 3 boxes, hidden

Pallet Load #2

B B B B B

A A A A B

B B B

OK! Pallet Load #1 is completed with "B" Level parts. Mixed Pallet Load #2 contains all "A" level parts + 1 carton of "B" level parts (which would not fit on pallet #1) and 1 carton of "C" level parts.

Pallet Load #1
Back Column, 3 boxes, hidden Back Column, 3 boxes, hidden

Pallet Load #2

B A A A B

A B B B B

NO GOOD! Pallet #1 should be completely filled with Part "A" before beginning to palletize Pallet #2.

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

21 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

o 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:

Pallet Load #1, Order 1

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

Pallet Load #2, Order 1

Back Column, 3 boxes, hidden

Pallet Load #3, Order 1

C C C

B B B B B

A A A A C

B B B

Back Column, 3 boxes, hidden

Pallet Load #1, Order 2

Back Column, 3 boxes, hidden

Pallet Load #2, Order 2

Back Column, 3 boxes, hidden

Pallet Load #3, Order 2

E E E D E

F F F F F

F F F F F

E F

F A

D A D

E F

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.

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

22 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

9.3

MASTER & MIXED LOAD GENERAL INFO MASTER PALLET LOAD LABEL o 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. o 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 MIXED PALLET LOAD LABEL o 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. o 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 MASTER & MIXED PALLET LOAD LABEL LOCATIONS o There shall be a minimum of 1 Master or Mixed labels for each pallet shipped. o 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. o 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. o Master Load Labels and Mixed Load Labels shall be placed so that they do not cover any of the cartons barcode (handling unit) labels.

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

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2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

o The diagrams below illustrate the placement of the Master and Mixed Load Labels on the final pallet load.

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

Master 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)

Yazaki North America, Inc., 6801 Haggerty Road, Canton, MI 48187

734-983-1000

24 of 24
2.1
YAOM-PES12-015W

YAZAKI NORTH AMERICA

WI No.: YAOM-PE-S12-015W
Component Supplier Packaging Guidelines for Standard Parts

Rev. Doc. Date

11/12/10

This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the most current revision is utilized.

10.0 ENVIRONMENTAL POLICY & SUBSTANCES OF CONCERN (SOCS)

Yazaki North America is committed to being a responsible corporate citizen by serving as an example in environmental protection and preservation. Packaging that the supplier selects affects the environment in multiple ways from production of the material to end/final use, and must be manufactured to permit reuse or recovery when packaging waste is disposed of. Recovery includes the recycling of packaging materials, separate composting of biodegradable packaging, and energy recovery through incineration. Suppliers should select packaging that: 1) Is created/manufactured from a renewable resource 2) Has limited effect on the environment during production and after end-use 3) Has the capability of being reused or recycled Fulfilling these packaging requirements will ensure that our operations and activities do not adversely affect the communities in which we operate and the environment in general. PROHIBITED PACKAGING MATERIALS & SUBSTANCES OF CONCERN o Suppliers shall NOT use the following items in their packaging due to environmental effects & concerns: EPS (Expanded Poly Styrene) - blocks, inserts, packing peanuts, etc. Materials containing lead, cadmium, mercury or hexavalent chromium

11.0 PACKAGING QUESTIONS & ISSUES

Packaging issues may be communicated to Yazaki Packaging Engineering by contacting Steve Giebelhaus, Packaging Engineer: steve.giebelhaus@us.yazaki.com