NSK Steering Systems America

Transcription

1 PAGE NO: 1 of 13 NSK Steering Systems America Supplier Logistics and Packaging Manual

2 PAGE NO: 2 of 13 Table of Contents 1 Scope General Communication Supplier contacts Supplier Exchange Electronic Data Interchange (EDI) Advance Shipping Notices (ASN s) Pay on Receipt Program Delivery Requirements General Delivery Problem Report (DPR) Premium Freight Inventory Management General Ramp-up Schedules Ramp-down Schedules and Obsolescence Management Method One Method Two Packaging General Returnable Packaging Pallets Labeling Requirements Preservation Shipping General... 13

3 PAGE NO: 3 of 13 1 Scope 1.1 General This manual specifies logistics and packaging requirements for suppliers to NSK Steering Systems America, Inc. (NSSA). All companies supplying production raw materials and components to NSSA shall comply with the relevant requirements of this manual, unless otherwise directed in the purchase order. All companies supplying MRO products to NSSA shall comply with the relevant requirements of this manual, unless otherwise directed in the purchase order. All suppliers to NSSA shall conform to the NSK Americas Terms and Conditions of Purchase, located at All suppliers to NSSA shall conform to the NSK Americas Supplier Quality Manual, located at 2 Communication 2.1 Supplier contacts Suppliers shall designate key contact personnel responsible for handling logistics support. Designated contact personnel shall be able to communicate in the English language. Names of contact personnel, their deputies and supervisors, shall be provided. s addresses, phone numbers, and fax numbers of contact personnel shall be provided. Key contact personnel shall have the necessary expertise to provide logistics support. Key contact personnel (or their proxies) shall be available on working days between 7am and 5pm (local supplier time). Outside of working hours, appropriate qualified staff shall be available for logistic emergencies.

4 2.2 Supplier Exchange PAGE NO: 4 of 13 When directed, suppliers shall utilize the Supplier Exchange web portal to retrieve releases, send Advance Shipping Notices (ASN s), and respond to Delivery Problem Reports (DPR s). Supplier Exchange can be located at the following address: Unless otherwise negotiated, production schedules will reflect 12-week planning and 4-week firm requirements. Supplier Exchange information is updated a minimum of once a week. Suppliers shall check Supplier Exchange a minimum of once a week to ensure requirements are understood. 2.3 Electronic Data Interchange (EDI) Suppliers are encouraged to utilize EDI with NSSA plants. Specific requirements and information will be provided upon request. 2.4 Advance Shipping Notices (ASN s) Suppliers shall generate ASN s for all mass production shipments. ASN s may be generated via Supplier Exchange or EDI. ASN s shall have one shipper number assigned. The NSSA Pack List generated at the time of ASN Entry shall be printed and accompany every shipment.

5 2.5 Pay on Receipt Program PAGE NO: 5 of 13 NSSA utilizes a Pay on Receipt Program for production suppliers. The shipper number will become the invoice number that payments will be processed against. Payments are processed every week per the supplier s payment terms. Suppliers that are part of the Pay on Receipt program do not need to send invoices to NSSA for payment. 3 Delivery Requirements 3.1 General NSSA requires 100% on-time delivery to releases. Failure to deliver required material and parts to schedule may result in financial penalties. Suppliers shall notify their NSSA contacts immediately if a delivery will be missed. 3.2 Delivery Problem Report (DPR) NSSA will issue a Delivery Problem Report (DPR) in Supplier Exchange for any shipping discrepancies. Suppliers shall respond to DPR s with appropriate corrective actions and countermeasures. NSSA will utilize DPR information when assessing suppliers for future business. 3.3 Premium Freight All materials and parts shall be shipped in accordance with NSSA requirements and transportation routings. Suppliers shall be responsible for transportation and freight costs that do not conform to NSSA requirements. Alternative shipping methods, regardless of cost, shall be utilized if an NSSA release cannot be met.

6 4 Inventory Management PAGE NO: 6 of General Suppliers shall have systems in place that facilitate access to and management of all levels of inventory finished goods, raw materials, and all levels of Work In Process (WIP). This shall include inventory being stored/processed at off-site facilities. Suppliers shall utilize First In / First Out (FIFO) inventory management. The supplier shall have a process to ensure the appropriate identification of all unusable or damaged material (obsolescence, scrap, returns, rejections, etc.). Storage and holding areas shall be clearly marked and easily distinguished. Suppliers shall have proper practices and controls in place (including cycle counting) to ensure accurate inventory numbers by location. Suppliers shall have and use designated storage locations for all material. Suppliers shall have a process to ensure physical inventory counts, if performed, are accurately reflected in inventory records. Suppliers shall have a process that ensures Bill of Material (BOM) records are maintained and accurate. Where assigned inventory locations exist, they shall be accurately identified with labels that are easy to locate, understand and update. Suppliers shall have one integrated system encompassing both perpetual inventory and associated financial functions (i.e., "one set of books") to ensure that inventory transactions and balances are accounted for properly. Suppliers shall have a process to control Maintenance, Repair and Operating (MRO) inventory. Suppliers shall have a process in place to coordinate "balanced out" inventories (e.g. those affected by engineering changes and programs that are being phased out) with both sub-suppliers and customers.

7 PAGE NO: 7 of 13 Suppliers shall have a process to identify and route defective/obsolete material to a rework or scrap location in a timely manner. Suppliers shall have a process that ensures defective/obsolete materials are segregated, and disposed of properly (e.g. reworked or scrapped) in a timely manner. Suppliers shall have a process to safeguard environmentally sensitive, easily damaged, and high theft material. 4.2 Ramp-up Schedules NSSA will fill out timing sheets for all new programs and update when changes are made. Startup notification sheets will be sent to all suppliers 6 months before Start of Production (SOP). Suppliers shall sign all sheets and return them in a timely manner showing acceptance of the ramp up numbers. Any issues with the ramp up schedule need to be communicated immediately. 4.3 Ramp-down Schedules and Obsolescence Management Method One The supplier will receive a build out part verification list four months prior to the end of the program. Any changes, additions or deletions shall be noted on the form. Circle any build out parts that can be returned or sold back. The form shall be signed and returned to the Production Control Specialist even if there are no changes. Suppliers shall be responsible for protecting NSSA s production schedule by maintaining production capability for all build-out parts throughout the ramp down period. Preliminary forecast data (SupplierExchange generated releases) will continue to be sent throughout the ramp down. These dates and quantities refer to planned NSSA usage, not planned shipping or order requirements. SupplierExchange releases do not consider on hand inventory, in-transit material, and on order material. Suppliers shall not use SupplierExchange forecast volumes for ordering raw material or level two components for build-out parts during the ramp down period.

8 4.3.2 Method Two PAGE NO: 8 of 13 The first left-to-ship requirement will be sent three months prior to the end of the program. The second left-to-ship requirement will be sent two months prior to the end of the program. NSSA becomes committed from the second left-to-ship requirement. Additionally, NSSA will fax updated build out yet-to-order requirements the Monday following each build out inventory or after any major customer changes so materials inventory can by monitored. The third and final left-to-ship requirement will be sent one month prior to the end of the program. NSSA will inventory all build-out parts prior to sending each left to ship requirement. Suppliers shall conduct internal inventories at the same time so that NSSA s left-to-ship requirements can be utilized in the material planning process. NSSA will inform suppliers of any supplemental requirements following the second and subsequent inventories. Supplemental requirements should be limited to scrap replacement, inventory miscalculations or customer changes. In order for NSSA to have a successful build out, effective and timely communication is critical. NSSA will fax or left-to-ship requirements following each build out inventory. 5 Packaging 5.1 General The supplier shall establish and maintain a procedure to assure that the NSSA packaging requirements are met. The supplier shall maintain documentation of all NSK Steering Systems America packaging specification requirements. This documentation shall be updated as appropriate. The packaging specification records shall also contain packaging acceptance and approval by the NSSA Purchasing Department.

9 PAGE NO: 9 of 13 The supplier shall develop packaging and dunnage which ensures that all parts are received free of damage. NSSA may assist with the initial packaging design and development but is not liable for any nonconformance of the final packaging. Packaging of all shipped materials must be robust enough to assure the proper condition and quality of parts therein upon delivery receipt to NSSA and 30 days past receipt. Parts must arrive at NSSA without damage, rust, corrosion, or contamination. The supplier shall complete the "Packaging and Shipping Data Form" prior to final packaging approval. Any subsequent changes shall require the resubmission of the "Packaging and Shipping Data Form." The supplier shall establish a designated contact to address any packaging issues as well as a shipping contact to address any transportation issues. All corrugated containers and palletized loads must be stackable unless part configuration and/or weight requirements do not permit this and prior written approval is received from NSSA. The supplier shall receive approval for temporary use of packaging that does not meet requirements. For non-conforming packaging, the supplier shall have a documented system for resolving customer problems. This plan shall establish a procedure for timely review of and response to packaging problems by appropriate supplier personnel. NSSA may enter a Delivery Problem Report (DPR) in SupplierExchange to address packaging concerns. The supplier shall establish a system and implement a procedure to audit the part count per container. The audits shall be conducted on a random basis by an individual other than the packer. Documentation of the audit process shall be maintained. The supplier shall have facilities adequate to meet packaging requirements. These facilities shall be well lit, adequately maintained, and adequate for the goods being packaged. Packaging shall not be stored outside. Manually handled packaging shall not exceed 40 lbs (18 kg) per container. Only one part number shall be packed per container. The supplier shall keep on a separate pallet and properly label all in-process parts, deviated parts, change-in-process parts, trial parts, design change levels and special order parts.

10 PAGE NO: 10 of 13 Wood containers shall comply with all appropriate regulations for treating and marking (e.g. ISPM 15). Failure to comply will result in a DPR and charge-backs for all related fines and handling costs. 5.2 Returnable Packaging Supplier will be directed to use returnable containers on a case-by-case basis. Returnable containers include modular packaging such as plastic totes, pallet boxes, plastic pallets and special containers such as racks, carts, vacuum formed tray packs and sleeve packs. The selection of the appropriate returnable containers used for each part will be determined by NSSA and the supplier. Manually handled returnable containers shall not exceed 40 lbs (18 kg) when loaded. When new parts or models are introduced, or new packaging is proposed, the supplier shall complete the "Packaging and Shipping Data Form. After approval by NSSA, the supplier shall conduct a test shipment to NSSA using a trial container with scheduled trial parts. All test shipments shall be clearly marked. The supplier shall notify NSSA Production Control personnel prior to any test shipments. The review process will be repeated until final NSSA approval is completed. If using returnable containers, the supplier shall establish a system for maintenance that includes the following: Cleaning Regular inspection Repair and modification Records for returnable container maintenance shall be maintained. The supplier shall maintain a supply (minimum of one day inventory requirement) of backup expendable packaging for shipments in case of delays in returning containers or shortages. Suppliers who need to ship parts in returnable containers shall receive authorization from Production Control at NSSA prior to shipping in expendable packaging. Authorization will only be given in emergencies.

11 PAGE NO: 11 of Pallets Production parts shall be palletized to allow handling by industrial forklift trucks. Pallets shall not be smaller than the length and width of the load. No product may overhang. The gross weight of any palletized unit shall not exceed 1,500 lbs (680 kg). Pallets shall allow 4-way entry with minimum openings of 2 ¾ inches high by 9 inches wide (7 cm high by 23 cm wide). Pallet dimensions shall conform to the Automotive Industry Action Group (AIAG) standard footprint of 48 inches by 45 inches (122 cm by 115 cm). The overall height of any palletized unit, including the pallet, shall not exceed 46 inches (116 cm). All packaging shall be secured to the pallet by the use of banding (plastic only) and/or stretch wrapping to prevent the load from shifting. Wood pallets shall comply with all appropriate regulations for treating and marking (e.g. ISPM 15). Failure to comply will result in a DPR and charge-backs for all related fines and handling costs. 5.4 Labeling Requirements Part identification shall conform to the Automotive Industry Action Group (AIAG) B-3 standard. Labels shall include the following fields in both English and bar-code form (see Figure 1). Part Number Part Description Revision Level Quantity Lot Code Supplier Name Supplier Number

12 PAGE NO: 12 of 13 The part number and description shall match the current repetitive purchase order or material release. Information on labels shall be consistent with the information on the approved "Packaging and Shipping Data Form." The supplier shall establish and implement an audit procedure to verify correct parts to labels. Part identification labels shall be applied to two adjacent sides of expendable containers. Any special labels shall be applied directly below part identification labels. Labels shall be clearly visible after containers have been palletized for shipping. Old labels shall be removed from returnable containers before shipping to NSSA. A master label shall be utilized with each shipment. The master label shall include the Supplier Number and the ASN number. See Figure 2. Figure 1 Figure Preservation The supplier shall establish and maintain material handling procedures that eliminate the potential for damage throughout all operations and transportation to NSSA. The supplier shall periodically audit material handling processes and equipment to ensure that damage is prevented to in-process parts and finished goods. At a minimum, the following items shall be reviewed: Appropriateness of transfer mechanisms and containers for the commodity produced. Parts damaged through in-house material handling. Process to address or resolve damage caused through material handling. All packaging and shipment methods shall ensure part shelf life of 30 days after receipt at NSSA.

13 PAGE NO: 13 of 13 6 Shipping 6.1 General The supplier shall ship all materials in conformance with NSSA requirements and transportation routings. The supplier shall maintain records that demonstrate specified routings and shipping methods are being followed. The supplier shall have facilities adequate for shipping and receiving operations. At a minimum, the supplier shall assure that: The number of doors or bays is adequate for shipping/receiving schedules. Dock areas shall be well lit, adequately maintained, and contain adequate space for shipping and receiving activities. The supplier shall audit shipments to ensure the accuracy of part numbers and quantities being shipped. NSSA will provide shipping carrier and routing information to suppliers. Any deviations to specified carrier and routing shall be authorized in writing. Excess freight charges will be debited back to suppliers if unauthorized carriers or routings are used. A DPR will be issued in SupplierExchange for unauthorized carrier and routing deviations.