QUIN GmbH Gutenbergstr Rutesheim. packaging manual

Transcription

1 QUIN GmbH Gutenbergstr Rutesheim packaging manual Last revised: January 2013

2 Contents 1. General information Objective of this manual Scope of this manual Supplier s obligations Packaging requirements Contact Packaging planning and specification Release process Flow chart for packaging planning Packaging materials Quantity of containers Packaging types Returnable packaging Universal load carriers Special load carriers Disposable packaging Bundles Special requirements for sea and air freight Sea freight Air freight Forming and securing loading units Forming loading units Stackability Shipping documents and container labelling Container labelling Single VDA label (210 mm x 148 mm) Single VDA label 4902 for small load carriers (210 mm x 74 mm) Contents of the VDA material tag Small load carrier labelling Delivery note CMR bill of lading or shipping order Annexes

3 1. General information The following guidelines and regulations for the supply of goods to QUIN GmbH and its plants are to be understood as a contractual agreement supplementing the general terms of purchase. 1.1 Objective of this manual This manual is to aid the development of optimal packaging that safeguards the smooth flow of materials between the supplier and QUIN GmbH with consideration to all quality, ecological, and economic aspects. 1.2 Scope of this manual This packaging manual applies to deliveries to the QUIN plants in Wałbrzych (Poland), Brașov (Romania), Wuqing (China), and Rutesheim (Germany). This packaging manual regulates the operations involved in the packaging of production parts, semifinished products, and commodities. 1.3 Supplier s obligations When not agreed otherwise, the supplier is obliged to deliver products in the standard packaging from the start of series production. An adequate quantity of packaging materials must be available at all times for shipping. The supplied containers must be filled to the maximum level. Changes to the filled level must be agreed with Quin GmbH. The prescribed labelling must be observed. Before they are reused, the load carriers must first be cleaned of contaminants like e.g. dust, soiling, moisture, etc., that may have an adverse effect on the quality of the components. Cleaning also extends to the removal of labels and label residue. Returnable packaging that cannot be cleaned may not be reused. Loading and unloading must not contaminate the load carriers or components. Quin containers may not be scrapped without the prior consent of Quin Logistics. The supplier is liable for additional expenses incurred through failure to observe these specifications. These incurred costs will be charged to the supplier in the form of repackaging and additional container fees. Moreover, Quin is entitled at any time to refuse acceptance of the delivery and to cancel the order. The costs of losses are offset against the replacement value. When the originator cannot be established, the costs are charged equally to each party. 2

4 1.4 Packaging requirements The specifications in this packaging manual and the national and international regulations must be observed. Disposable packaging is used after agreement and primarily for overseas shipping, replacement parts supplies, and pilot runs. Quin GmbH reserves the right to refuse acceptance of consignments that are not delivered in the agreed packaging. Irrespectively of the packaging type chosen, the packaging must fulfil the following requirements: The packaging must be such that the components arrive undamaged at the recipient. Visible surfaces may not come into contact with the packaging at any time over the transport route. When corrosion protection is required, it is the supplier s responsibility to provide for adequate packaging. Consignments must be placed exclusively in clean packaging. This should allow ease of cleaning and not pose a danger to persons. The containers should be filled for the optimal balance, and their bundles must allow stacking. There must be adequate stability. Loading and unloading must be simple and also allow the use of ground conveyors. The supplier is responsible for adequate transport locks. The packaging must allow ease of handling and ergonomic withdrawal of contents. Standardised labelling must be observed for the correct identification of the components. Only one reference number may be packaged in each loading unit. Deviations must be agreed with Quin GmbH Logistics Planning. 1.5 Contact The contact in the planning phase is Logistics Planning. The standard packaging is supervised by the affected user departments at the production plants. All contacts are listed in Annex 1. 3

5 2. Packaging planning and specification The packaging is specified at all times by the supplier that bases its choice on the requirements in the QUIN packaging manual. 2.1 Release process The packaging is set down in writing on the packaging data sheet (see Annex 3). All new or changed packaging specifications are sent to the supplier who must complete and return the sheet to Quin GmbH within fifteen working days. Until further notice, the packaging is valid for all change indexes. It becomes legally binding when undersigned by the supplier and the responsible logistics planner at Quin GmbH. The release of packaging does not exempt the supplier from its responsibility to deliver parts free of damage. QUIN reserves the right to determine its packaging service provider. Deviations in justified cases (e.g. pilot run packaging for reruns) must be agreed with Quin GmbH before delivery. 4

6 2.2 Flow chart for packaging planning QUIN Supplier 5

7 2.3 Packaging materials The supplier must develop environmentally friendly packaging complying with the regulations in the affected country. This must be designed for the volume of the components and consist of environmentally compatible, recyclable materials. Quin GmbH introduces disposable packaging to suitable recycling processes. The disposal of returnable packaging is specified from project to project. Overview of QUIN approved materials: Material Approved materials Forbidden materials Composites Composites are not permitted General plastics Disposable PE, PP, PS, PET marking under DIN 6120 PVC, expanded polystyrene Returnable PE, PP, PET, ABS marking under DIN 6120 PVC, expanded polystyrene Plastic packaging material Precut plastic sheeting Bags and sacks Protective and insulating caps Deep drawn inlays Foams PE PE PE PE, PP, PS, PET, ABS PE (returnable also PP) Cardboards and paper Marking and administration must comply with RESY With water insoluble coatings (e.g. wax, bitumen, oil paper, self adhesive paper tapes) Strapping PP, PET Steel strips, polyamide strips, polyester strips Anticorrosion paper Only VCIs whose recyclability with paper/card has been verified Wood In accordance with IPPC, ISPM15 Pressboards / pressboard pallets Impregnated, painted, coated wood Stuffing Corrugated cardboard, paper Chips of vegetable products Chips or shaped parts of expanded polystyrene Table 1 Packaging materials 6

8 2.4 Quantity of containers When using returnable packaging, the supplier must determine the required quantity of containers and agree this with QUIN. The number of containers determined is based on circulation days (CDs). The supplier is obliged to specify the circulation days in accordance with the table below. Supplier Carrier QUIN Production Transport Warehouse for full products 1 CD 2) 3 CD Delivery cycle Delivery cycle X CD1) X CD1) Safety stock X CD3) Production 1 CD Warehouse for empties 1 CD 1) For delivery cycle 1 x week: 2.5 CD 2 x week: 1.5 CD 3 x week: 1 CD 2) In Germany: 1 CD Between Germany and Poland 1,5 CD Between Germany and Romania 3 CD In case of empties return please multiply by 2. 3) For EU: 1 CD For Europe (non-eu): 3 CD Rest of the world: 5 CD Table 2 Calculating circulation days Adding each of these process steps returns the circulation days. 7

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10 3. Packaging types The target is the consistent organisation of the logistics chain with standardised packaging and the utilisation of the associated potential in partnerships. Depending on the quality and handling requirements, either universal or special load carriers are used. 3.1 Returnable packaging Universal load carriers The small and large load carriers used differ from project to project and must be agreed with Logistics Planning. The components must be protected against damage, moisture, dust, and soiling as described in the packaging requirements. This can take the form of spacers, interim layers, or sheeting and an adequate plastic cover. Small load carriers must comply with the VDA standard. The top layer of small load carriers must be provided with a plastic cover, and the layers filled whenever possible over their whole surface. The following small load carriers can be used: KLT 4314 (400 x 300 x mm) KLT 6414 (600 x 400 x mm) KLT 6428 (600 x 400 x 280 mm) Special load carriers A special load carrier is used when universal load carriers are not possible. Following agreement with the Quin GmbH user department, the supplier plans, designs, and procures the special load carriers. Special load carriers are also large and small load carriers with inlays adapted specially to the component. These can consist of various materials that are listed in Section 2.4. Figure 2 EPP foam Figure 2 Deep drawn insert in a small load carrier 9

11 3.2 Disposable packaging Disposable packaging is developed and procured by the supplier. Disposable packaging is used following agreement and only when load carrier returns entail high costs, e.g. for overseas shipping, replacement parts supplies, or pilot runs. Planning must take into account the following: The packaging must be such that the components arrive undamaged at the recipient. Visible surfaces may not come into contact with the packaging at any time over the transport route. If necessary, they must be provided with an adequate protective sheet. When corrosion protection is required, it is the supplier s responsibility to provide for adequate packaging. Disposable packaging is generally provided by the supplier and is charged to the supplier s account. The standard measurements of the loading unit and its modular layout must be adapted to the recommendations under VDA 4500 and Deviations must be agreed with QUIN Central Logistics. The sealing aids used must be suitable for the size and weight of the packaging unit. Loading units should allow two-high stacking. 3.3 Bundles Bundles are made up of several single constituents, e.g. pallet, small load carrier, top cover. 4. Special requirements for sea and air freight 4.1 Sea freight The packaging must be such that the effects of cold, moisture, or heat and the extreme loads caused by goods movements cannot prove detrimental to the product quality. In addition, the packaging should exhibit a space saving, convenient design that is suitable for loading with ground conveyors. At the same time, the measurements and weights must be adapted under economic aspects to all transport means in the logistics chain. The provisions applying in the countries of destination must be observed. 4.2 Air freight Air freight consignments should be placed in space saving, lightweight, and robust packaging that must also protect the goods from extreme climatic and mechanical effects both to and from the airport. 10

12 5. Forming and securing loading units A loading unit is a shipment whose constituents of objects and packaging aids are such that they can be handled, transported, stacked, and placed in storage as a single unit. 5.1 Forming loading units The basic size of loading units may not be exceeded by the packaged goods or the units themselves. They must allow at all times their handling by ground conveyors and automated conveying installations. The measures for securing the loading units must not restrict the access height for forklifts. The loading units must be secured to prevent the packaging from slipping during transport. Possible measures are: pallet cover top plastic strapping Strapping must not cut into cardboard packaging. Angle beads must then be used here. Withdrawing parts of a loading unit s contents must not affect the stability of the remaining contents. 5.2 Stackability When the quantity released cannot fill completely a layer, this layer must be filled with empty containers. Empty containers must then be labelled as empty. Wrong Wrong Right Wrong Right 11

13 6. Shipping documents and container labelling 6.1 Container labelling Container labels serve as a unique ID for the goods and unit load devices both for the inhouse material flow and on the transport route between supplier, carrier, and consignee. The supplier must therefore ensure that all unit load devices are provided with an up to date, carefully completed, and barcoded material tag complying with VDA recommendation 4902 (current version). In particular the details on the material tag must agree with the contents of the unit load device. For the purpose of unique IDs, the supplier is obliged to remove completely all outdated material tags and labelling on the unit load devices before they are filled. In the event of absent, illegible, or incompletely filled material tags, QUIN reserves the right to bill any additional expenditure incurred by this failure to comply with the labelling provisions. The supplier can likewise be billed for any additional expenditure incurred as a result of incompletely removed material tags, incorrect securing, or other violations to the regulations contained in these logistics guidelines. VDA recommendation 4902 describes the following two formats. 6.2 Single VDA label (210 mm x 148 mm) Q1 12

14 6.2.1 Single VDA label 4902 for small load carriers (210 mm x 74 mm) Contents of the VDA material tag Field number Field name Example 1 Consignee QUIN GmbH Rutesheim 2 Unloading point storage location distribution key S 3 Delivery note no Supplier address Some Company Ltd, Some City 5 Package weight excl load carrier (kg) Package weight incl load carrier (kg) Number of packages for this delivery 1 8 QUIN reference number Actual filled quantity Name, delivery, service (name of the goods) LST W Container reference number Supplier number (customer reference number) Date 22/10/ Design change status Package number Batch number (that the manufacturer assigns to a batch or production lot) /1-1 13

15 6.2.3 Small load carrier labelling The container label in the VDA card pocket must be attached to an easily visible site on the face or long side and may not project over the outside edge of the packaging. The material tag chosen must be resistant to environmental effects and the transport environment so that it can be machine read at the delivery point. In addition, the container label can be secured with max four adhesive film strips or points that can be detached without residue. 6.3 Delivery note The collection of materials at QUIN goods receipt requires a delivery note that provides a unique description of the delivery. The delivery notes for each shipment must be: a) affixed securely and in duplicate in adequate sleeves to the outside of their packages when the consignment is shipped via a parcel service. b) handed over together with the freight documents to the driver when the consignment is shipped by carrier. The delivery notes must contain at least the following: delivery note number name and address of the sender name and address of the recipient date of the delivery note name or possibly signature of the packager gross weight, net weight delivery note items name of the orderer (contact person) purchase order number purchase order date purchase order item QUIN article reference QUIN article description supplier s article number delivery quantity (per purchase order item) in quantity units 14

16 6.4 CMR bill of lading or shipping order The shipping order serves Container Control as a basis for regular account reconciliation and as a control instrument for the examination of container quantity and quality at goods receipt. The shipping order used must comply with VDA This requires complete, correct, and unique details that must be entered on the shipping order as follows: consignor loading site supplier no. shipment, loading, reference no. packaging type number of containers The driver or carrier confirms with its signature the proper condition and completeness of the shipment. The supplier must provide shipping documents that have been completed properly. The supplier must bear the costs for acquiring details that are not included on the shipping documents. 15

17 7. Annexes Annex 1: Contacts at central QUIN logistics Rutesheim Annex 2: Contacts at plants Annex 3: Packaging data sheet 16

18 Annex 1: Contacts at central QUIN logistics Rutesheim Name/position Phone QUIN Rutesheim Ms Drulea Logistics Planning Mr Müller Logistics Management Mr Fey Operative Logistics Annex 2: Contacts at plants Name/position Phone QUIN Romania Ms Reimesch Logistics Management Mr Godri MRP Name/position Phone QUIN Poland Ms Pisla Logistics Management Ms Novosielska MRP Ms Orlon MRP Name/position Phone QUIN China Mr Thurner Executive Management

19 Annex 3: Packaging data sheet Verpackungsdatenblatt Kunde Lieferant Kunden- / Lieferantendaten Quin GmbH Firma Firma Adresse Adresse PLZ, Ort PLZ, Ort Land Land Kontaktperson Kontaktperson Abteilung Abteilung Telefon Telefon Telefax Telefax Verkäufer Lieferant Einkäufer Status Verpackungsdatenblatt: Erstellungsdatum: Sachnummer Lieferant: Entwurf Freigabe Fertigungslosgrösse: Stapelfaktor Verpackung (befüllt): Befüllung Verpackung: manuell automatisch Teile-Bezeichnung: Sachnummer Arau: Teile-Gewicht (kg): Empfängerwerk: Laufzeit: Lieferfrequenz: Jahresmenge: Verpackungsdaten Aussenmasse Verpackung befüllt (mm): Volumen (m³): Stück / HU (Palette): Holzstab Kunstofftiefziehlayer Deckel KLT Bezeichnung Verpackungsbestandteile Kunststoffband Aussenmasse Verpackung Leergut (mm): Gewicht (kg) 1 = Einweg 2 = Mehrweg Sach-Nr. Volumen (m³): Stück / Behälter: Masse (mm) Anzahl / Tara Gewicht / Währung: Lieferant Verpackung L B H HU HU (kg) Preis/Stück Preis/HU Einweganteil pro Palette Werkzeugkosten Verpackung Mehrweganteil pro Palette Armortisation nach Stück Entspricht Amortisation in Jahren Anteilige Verpackungskosten / Komponente Bedarf Mehrwegverpackung Schwund, Defekte Mehrweganteil pro Stück Umlauftage entspricht HU % entspricht HU Einweganteil pro Stück Tara Gewicht Netto Gewicht Brutto Gewicht Invest ohne Verzinsung Zinssatz (%) Verpackungskosten pro Stück gesamt Invest mit Verzinsung Verpackungsdatenblatt Kunde Lieferant Status Verpackungsdatenblatt: Erstellungsdatum: Stapelfaktor Verpackung (befüllt): Entwurf Freigabe Teile-Bezeichnung: Sachnummer Quin: Teile-Gewicht (kg): Bezeichnung Verpackungsbestandteile Anzahl/ HU 1 = Einw eg 2 = Mehrw eg Zusätzliche Vereinbarungen Beschaffung der Verpackung Leihgutkonto für Mehrwegverpackungen Quin Quin KU / LI KU / LI Lagerung der Verpackung in freiem Gelände Verpackungskosten im Teilepreis enthalten ja ja nein nein Reinigung der Verpackung Quin KU / LI Beschriftung nach Arau Vorschrift ja nein Leergutrücktransport Quin KU / LI KU = Kunde / LI = Lieferant Verpackungsdaten Aussenmasse Verpackung (mm): Volumen (m³): Stück pro Palette: Aussenmasse Verpackung Leergut (mm): Volumen (m³): Tara Gewicht Netto Gewich Brutto Gewicht Anlieferungszustand / Leergutrücklieferung (Erforderlich bei Einsatz von Mehrwegverpackungen) Foto 1: Inlet Foto 2: KLT Foto 3: Befüllung Foto 4: Versandbereit/ Foto 3 Befüllung Foto 2 Befüllung Foto 3 Versandbereit Foto 3 Leergutrücknahme 18