Pallet Quality in the 21 st Century. Ralph Rupert Millwood Inc Manager Unit Load Technology

Transcription

1 Pallet Quality in the 21 st Century Ralph Rupert Millwood Inc Manager Unit Load Technology

2 Objectives Discuss increasing customer expectations Development of a quality system Introduce revised ANSI Pallet Standard

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11 Customer Expectations ISO 9000 Customer quality survey Work Instructions PPAP Production Part Approval Process Food Modernization Act Covered storage Workplace issues Documentation

12 Quality Survey Example Often it is a one size fits all form Multiple sections Quality Management System Supplier Qualifications/ Incoming Materials Pest Control Traceability and Recall Calibration of Equipment Foreign Materials Self Improvement Employee Training Building and Ground (include Security) Product Storage and Shipping Equipment Food Safety Pallet Production and Quality

13 Section 1: Quality Management Systems M PM DNM NA Are specifications for products and/or services defined and are they documented? (There should be Written Specifications agreed upon by ABC and the pallet supplier). Does the pallet supplier understand the importance of consistently meeting specifications to ABC? Does ABC have all the appropriate documentation required? This may include but is not limited to: Product Specifications, Safety Data Sheet, Letter of Continuing Guarantee, Product/Materials Origin, etc. (the auditor should make sure that ABC has most recent issues.) 1.3 How does the pallet supplier ensure they consistently produce or sell a quality product? How does the supplier ensure they meet ABC specifications? Who is Responsible for Quality? How does management monitor quality? Describe in detail: 1.4 Is there an adequate communication structure to ensure that the pallet suppliers management receives feedback from employees and ABC regarding quality issues? 1.5 Is there a system for handling customer complaints? How does the pallet supplier make sure they get address complaints and that corrective actions identified from complaints are performed? 1.6 Has the supplier identified any risks their pallets could present to ABC? Does the supplier understand that their products could bring potential hazards into an ABC facility? (Explain)

14 Section 8: Employee Training Does the supplier have a training program for employees? (Explain): Are there any topics that could affect ABC (examples: incoming materials inspection, loading finished product truck inspection)? Is the training conducted prior to starting employment and at least annually thereafter? Does the supplier have documented rules? Do the rules cover outside contractors, visitors, and temporary employees? M PM DNM NA

15 Section 9: Building and Grounds (including Security) Is the plant in good repair (cracks/crevices/holes in floors, walls, ceilings)? Are there any issues with the 9.1 plant that could cause contamination issues for ABC products? Are the grounds free of general litter, trash, overgrown weeds, standing water, used equipment, old pallets? 9.2 Are there any issues with the grounds that could cause contamination issues for ABC products? 9.3 Does the plant have a procedure for visitors? 9.4 Does the plant have appropriate security? M PM DNM NA Section 10: Product Storage and Shipping 10.1 How is lumber stored? How is it selected for use? Is FIFO used? Are construction materials free of dust and damage? Are construction materials stored so they do not pick up 10.2 or absorb contaminants? Are materials inspected prior to use? Does the pallet supplier have a rework policy? Is rework 10.3 and off spec material properly identified and segregated? 10.4 How are Lots of finished pallets designated? 10.5 Are Pallets stamped to show treatment methods? 10.6 Are finished pallets stored to prevent contamination? 10.7 Are trucks /rail cars inspected prior to loading? Are the inspections documented? M PM DNM NA

16 Section 11: Equipment M PM DNM NA 11.1 Does the plant have a preventative maintenance schedule? 11.2 Is equipment in good repair and made of appropriate material? Are there any housekeeping issues that could affect ABC products? Are all product contact materials maintained in appropriate condition? Are chemicals and lubes securely stored and used so as not to create issues? Are there any chemicals that should not be in the plant? Are there any concerns with chemical control? Section 12: Food Safety M PM DNM NA 12.1 Pallet Companies will not have HACCP plans. They should understand how their products could affect ABC product and if there is any risk to ABC products. What controls does the company have in place to ensure that their products are safe for ABC to use? (Explain):

17 Section 13: Pallet Production Questions Timber/Wood Pallets In a 4 way perimeter base pallets, is every base board fastened at each end with two or more mails of 13.1 correct length and diameter with adequate edge distance? Are the stringer and deck boards made of sound 13.2 timber, or are there excessive knots? Are the deck boards, stringer boards, and base boards 13.3 to the required thickness and width of the purchaser's specifications? 13.4 Are the base boards split at their fastened end? 13.5 Are there damaged bearers or blocks? Are there projecting nails or nails pulled through deck 13.6 boards? 13.7 Are there edge splits in any board members? Are there loose joints permitting racking out of square 13.8 (diamonding)? 13.9 Are the pallets clean and free from contamination? Are the pallets heat treated (HT)? Did the pallets reach the specified time/temperature industry standard? Are the pallets fumigated? Did the pallets reach the specified time/temperature industry standard? Are the chemicals used for both pallets treatments approved by the FDA? What are they? Does the supplier use reconditioned and/or rework pallet materials back in their process? When was their last American Lumber Standard (ALSC) inspection of the facility? Was there any corrective or preventative actions? M PM DNM NA

18 Quality Documentation Specifications Daily audit form to verify work Storage Housekeeping Pest Control Work area free of food Work instructions and training Preventative maintenance

19 ANSI MH1 Pallet Standard Committee members include pallet manufacturers, users, academic, military, and interested parties Ralph Rupert Millwood (chair) - Brad Gething - NWPCA John Conway Conway&Robinson - Mark Rehmstedt - DOD John Clarke Nelson Co - Tim Keller - DOD Mark White White & Co - Laszlo Horvath - VT Chris Merther ITA - Gary Sharon Litco Sanjiv Takyar - CHEP - Don Balazs Orbis Dan Steppan UL Labs - John Healy - Consultant

20 ANSI MH1 Pallet Standard Latest revision Still contains the NWPCA Uniform Standard Added parts for plastic, metal, paper, and presswood pallets Desire to have all materials meet same test protocol and performance guidelines Military specifications in Part 9

21 ANSI MH1 Pallet Standard

22 Repair Quality New definition of a B (#2) Anything that does fall apart when stacked Up to 8 stringer repairs Can be confused with Grade G Send to grinder Anything the customer will pay for

23 Question?????

24 Thank you For More Information: Ralph Rupert Manager Unit Load Technology

25 Standard Quality Standard list dimension variability as basically 1/16 and 1/8 Are we truly holding this. Customers are starting to monitor Bandsawn material seems more variable Fastener quality should be monitored