GDLS-C PACKAGING GUIDELINES

Transcription

1 GDLS-C PACKAGING GUIDELINES GENERAL DYNAMICS Land Systems-Canada

2 GENERAL DYNAMICS LAND SYSTEMS CANADA PACKAGING GUIDELINES ISSUED: May 8, 2009 This document has been prepared by General Dynamics Land Systems Canada to assist our suppliers with the packaging of material used in our plants. This document is applicable for shipments to General Dynamics Land Systems Canada London, Ontario as well as any other General Dynamics destination identified on the purchase order. If you have any questions, please contact your General Dynamics Land Systems Canada Supply Chain Management representative. Supplier conformance to these Packaging Standards is mandatory. When vendor packaging material does not meet the criteria as described in the standard, it causes a safety and a material handling problem within GDLS plants. Therefore, any received material requiring additional handling as well as repackaging will be assessed and the labor and material cost at the current GDLS rate will be charged to the vendor. Unless otherwise specified or directed, the following packaging guidelines are to be adhered to by all General Dynamics Land Systems Canada Suppliers beginning with the receipt of this manual. These packaging guidelines support the GDLS C GREEN (Growth through improvement; Reduce, reuse, recycle; Everyone is responsible; Eliminate waste; Never break the law) Program. New ergonomic packaging guidelines support continuous improvement with respect to safety. These guidelines are based upon sound engineering principles, customer input and the latest in packaging technology. Notice of Liability and Caution The information in this manual is distributed on an as is basis, without warranty. While every precaution has been taken in the preparation of this manual, the authors shall not have any liability to any person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual. It remains the responsibility of the users of this manual to establish appropriate safety and health practices and to determine the applicability of regulatory requirements in conjunction with it s use. These standards are subject to periodic review and users are cautioned to obtain the latest edition. This document supersedes EMD document: GMLG PACKAGING REQUIREMENTS, Issued February 8, Prepared by: GDLS Packaging, Handling, Storage and Transportability GDLS Supply Chain Management GDLS Environmental GDLS Ergonomics

3 INDEX GDLS C PACKAGING GUIDELINES (P.O.C.) Pg. 3 GENERAL PACKAGING INFORMATION Pg. 4 PRODUCTION PACKAGING GUIDELINES Pg. 5 SERVICE PARTS ORGANIZATION PACKAGING GUIDELINES Pg. 6 CONSIDERATIONS FOR ENVIRONMENTAL PACKAGING Pg MANUAL MATERIAL HANDLING GUIDELINES Pg MECHANICAL MATERIAL HANDLING GUIDELINES Pg HAZARDOUS MATERIALS PACKAGING REQUIREMENTS Pg. 23 2

4 GENERAL DYNAMICS LAND SYSTEMS CANADA PACKAGING GUIDELINES (P.O.C.) General Dynamics Land Systems Canada, London Operations, PO Box 5160 London Ontario, Canada N6A 4N5 GDLS C Packaging Contact Dial: GDLS C Heat Treated Wood Packaging Contact Dial:

5 GENERAL DYNAMICS LAND SYSTEMS CANADA GENERAL PACKAGING INFORMATION INTRODUCTION General Dynamics Land Systems Canada manufactures Military Defense Vehicles through production contracts and supports these vehicles with comprehensive aftermarket service contracts through the Service Parts Organization. In order to support these contracts in the most cost effective manner it necessitates a division between Production orders and Service Parts Organization (SPO) orders in regards to packaging. When shipping parts to GDLS C the packaging requirements for a Production Order and an SPO Order will be different. The following guidelines will provide the required direction in order to ensure that shipments are sent with the proper packaging in place. Some of the packaging directions for SPO orders may conflict with the environmental suggestions otherwise specified in this document but these packaging directions are specified for long term storage, potentially several years, and must provide adequate protection to the item through multiple handling operations during this timeframe. SUPPLIER COMPLIANCE TO THESE GUIDELINES Supplier compliance to the guidelines in this manual is mandatory. Failure to comply will produce the same reaction as non conforming parts, namely a PRR being issued against the supplier which will need to be addressed in the same timely manner. Information on the PRR system and associated procedures can be obtained through the Supplier s Purchasing Department Representative or QA Representative at General Dynamics Land Systems Canada. Many parts supplied to General Dynamics Land Systems Canada are of a configuration that requires special packaging consideration not covered within this manual. If you are the supplier of these types of parts, you are required to contact the Packaging P.O.C. at for assistance in development of a package compatible with General Dynamics Land Systems Canada Material Handling processes. Gross weight per pallet/unit load should not exceed 3,000 lbs. Contact General Dynamics Land Systems Canada Handling/Packaging Representative for alternative handling of heavier material. Packaging is mostly common sense send parts as you would like to receive them. You can produce the most cost effective correct part possible, but if you fail to package or preserve it correctly you are non compliant. 4

6 GENERAL PACKAGING GUIDELINES ALL SHIPMENTS Any wood packaging used must comply with the Canadian Food Inspection Agency requirements for import and export as our facility is registered to produce ISPM No.15 compliant wood packaging material and must maintain certain standards. Refer to the Canadian Food Inspection Agency website to ensure proper requirements are met. All pallets used for shipments must be Heat Treated and Stamped as such. The pallet must be in good condition and capable of standing up to the weight of the load being shipped. 5

7 PRODUCTION PACKAGING GUIDELINES All material shall be suitably packed, marked and shipped in accordance with the requirements of the carriers in a manner to secure lowest transportation cost. Any additional charges other than that which is on the General Dynamics Land Systems Canada Purchase Order requires prior approval. Bulk packaging is allowed and encouraged for production shipments. Parts shipping for production requirements require minimal packaging, however the parts should arrive at GDLS C facilities without damage and in a similar condition as when they were shipped. All containers must have a copy of the packing slip attached and included in the shipment. Items highly susceptible to corrosion will need a short term preservative applied to prevent corrosion occurring while in transit and storage prior to assembly on the vehicle. Any item stripped of residual oils for the purpose of painting must have a preservative applied prior to exposure to the environment as these items will corrode quickly. Containers must be of suitable construction to hold parts securely during shipping and handling. Any component requiring special packaging due to EMD/ESD or similar requirements must be properly packed and shipped to ensure the parts integrity. Returnable containers must be clearly marked Returnable. Shipment of returns back to suppliers can be arranged through the Transportation Department. 6

8 SERVICE PARTS ORGANIZATION (SPO) PACKAGING GUIDELINES These guidelines are based on ASTM D 3951 Standard Practice for Commercial Packaging specifications and are the most commonly accepted industry standard. SPO orders require some special considerations for packaging as these parts will be consumed by customers for the purpose of repairing damaged or non serviceable parts on vehicles. Repair and Overhaul (R&O) orders fall under this category and also must be individually packaged for return to the customer. Contact GDLS C buyer or PHS&T representative for specific requirements. All material shall be suitably packed, marked and shipped in accordance with the requirements of the carriers in a manner to secure lowest transportation cost. Any additional charges other than that which is on the General Dynamics Land Systems Canada Purchase Order requires prior approval. All parts should be individual packed in a unit container consisting of a poly bag, fibreboard box, or wooden crate depending on the size and weight of the item in question. This does not include common fastening hardware. Items such as nuts, bolts, washers & plastic tie wraps may be bulk packed in quantities up to 100 pieces per unit container. Contact your General Dynamics Land Systems Canada Handling/Packaging Representative at , if further clarification is required. All packaged items must be identified in the form of a label consisting of the Part Number and Part Description from the Purchase Order as well as the quantity of parts in the container. All items that have the potential of corroding while packed and in storage must be preserved with a corrosion preventative material such as VCI paper, VCI film or suitable rust preventative coating that will ensure the parts integrity for a minimum of 1 year. Contact your General Dynamics Land Systems Canada Handling/Packaging Representative at , if further clarification is required. Suppliers are encouraged to discuss packaging and shipping methods with the General Dynamics Land Systems Canada Packaging, Handling, Storage and Transportation (PHS&T) Representative prior to finalizing packaging designs (particularly if the parts are being provided for the first time). Unique packaging requirements dictated by part characteristics such as rust prevention, weight, fragility, and surface appearance which are not covered by these guidelines are the responsibility of the parts supplier and must be approved by the General Dynamics Land Systems Canada Handling/Packaging Representative. Any item that has a shelf life must have that information provided on the packaging label. Serialized items require the serial number to be displayed on the exterior of the container including this information on the label is optimum. 7

9 Considerations for Environmental Packaging 1 Corrugated pallets are not acceptable as they do not stand up well for the type of products we are handling. 2 Wire bound crates or boxes must not be used in favor of pallet cartons constructed with a breakaway feature or other method to allow easy separation from the shipping pallet. 3 Wood is not to be stapled to the corners, walls or top of any corrugated box. 4 Foam glued to corrugated and other dissimilar packaging material bonded together is not allowed. The use of foams and foam sheeting are to be minimized. 5 Expanded polystyrene (EPS) must not be used as an expendable packaging material. 6 Plastic strapping must be color coded. 7 Unitizing adhesives are strongly encouraged as a replacement for stretch wrap or strapping. 8 Use clear (non tinted), low density polyethylene stretch film (LDPE). 9 Identify rigid, moulded plastic with the proper resin code. 10 Use of wasteful, excessive and non recyclable materials is considered as unacceptable packaging. 8

10 Environmental Packaging Suggestions 1: PALLETS GDLS C Phytosanitary Requirements for Softwood and Hardwood Packaging: In order to comply with phytosanitary requirements of Canada (import side of Canada policy number D 98 08, using current revision) and for the European Union (or other countries that have similar requirements policy number D 01 05, using current revision) of the Canadian Food Inspection Agency (CFIA) the following must be adhered to. All soft wood/hardwood lumber, crates, dunnage, pallets, skids open wood crates and spools must come from an approved source and must have been heattreated to a minimum core temperature of 56 C for 30 minutes. Corrugated pallets are not acceptable as a substitute for wood. Where economically feasible, we encourage the use of returnable pallets constructed of steel or recycled plastics. GDLS C will continue to accept used structurally sound Heat Treated wood pallets. The disposal or recycling of wood pallets continues to be a challenge for our plants to manage. Our plants will continue to receive wood pallets that are in good condition, and efforts are being made to reuse or recycle as many as possible. (See page 21 and 22 for Pallet Information). 9

11 Environmental Packaging Suggestions 2: PALLET CARTONS Wirebound crates, wooden boxes and pallet cartons (corrugated flanged tubes bottomfastened to a pallet) are often used for bulk shipments. Wire bound crates and wooden boxes are generally not recyclable and our plants ability to separate the two materials used is impaired by the fastening process. Improvements in the pallet carton design that allows quick and effective disassembly of the corrugated sleeve from the pallet is required. ALL WIREBOUND CRATES AND BOXES ARE DISCOURAGED IN FAVOR OF PALLET CARTONS. PALLET CARTONS MUST BE CONSTRUCTED WITH A BREAKAWAY FEATURE OR OTHER METHOD TO ALLOW EASY SEPARATION FROM THE SHIPPING PALLET. This concept involves simple die cut areas (generally U shaped ) perforated and spaced along the lower flanges with the open end of the U facing the center of the pallet. The corrugated is stapled to the pallet within these areas. Four hand openings, die cut flaps in the sleeve, one per side, allow for lifting the sleeve from the pallet when disassembly is required. Printing on two panels is required to identify this feature. Two inch high bold type, for example states BREAKAWAY, FAST BREAK, ETC. The bulk corrugated container is affixed to the wood pallet by stapling within the die cut areas on the bottom flange. The container is disassembled by inserting the hands into the access holes and lifting upward, tearing the carton in areas where the die cuts are positioned. The carton separates from the pallet leaving only small pads of corrugated on the pallet base. NOTE: Consistent, correct assembly of the carton ( i.e. stapling inside the Die cuts and using corner kick ins to contain wood supports) Requires proper explanation/training of the carton assembler. 10

12 Environmental Packaging Suggestions 3: CORNER SUPPORTS All corrugated cartons are to be recycled after use. Any contaminant such as wood that is fastened to the corrugated material requires intensive and costly labor to separate. Wood is not to be stapled to the corners, walls or the top of a carton. ALTERNATIVES: 1. Eliminate the wood if possible. The carton strength may be acceptable as constructed. 2. If required, replace the wood with formed paper corner structures, or corrugated supports. These paper corners may be stapled in place, since they can be recycled with the sleeve. The use of solid angle fiberboard with a white clay coating and nonwater soluble adhesive is not to be used as a corner support. 3. For additional stacking strength, wood may be used in the corners as a support but must not be stapled to the corrugated. Other methods of holding the wood in place must be used, allowing ease of wood removal. Corner kick ins or corrugated pockets will suffice. Metal staples are acceptable for use as a carton closure. 11

13 Environmental Packaging Suggestions 4: FOAM DUNNAGE & DISSIMILAR MATERIALS Foam dunnage protects parts from abrasion, part to part contact, and protects items in transit. Currently, we have no economical solutions for recycling foam, which causes us to landfill the material or, return the dunnage to the suppliers at their expense. The use of foam or foam sheeting as an expendable material is discouraged. The following CANNOT be used as expendable packaging: 1 Foam glued to corrugated fiberboard and any other dissimilar materials bonded together. 2. Expanded Polystyrene (EPS) SPI Code #6 (includes pieces, sheets or loose fill). ALTERNATIVES: 1. Eliminate the foam or replace it with other easily recycled materials such as die cut corrugated or molded kraft paper pulp. 2. Sensitive part surfaces placed near corrugate may require recyclable polyethylene film or bags, or re pulpable coatings on the corrugate surface. (Wax coatings and foam sheeting is undesirable.) 3. Foam attached to corrugated fiberboard or other dissimilar materials must have an allowance for ease of removal. 4. Reduce the amount of foam used for cushioning to a minimum. 5. Foam in place packaging is discouraged, unless authorized by your GMLG representative. Foam is a relatively expensive material for one way shipment of components. Many suppliers are continuing to use the above alternatives to reduce their packaging costs. 12

14 Environmental Packaging Suggestions 5: STRAPPING While metal strapping continues to be acceptable, we recognize that non metallic (plastic) strapping is available in various materials that satisfy requirements of tensile strength, elongation and recovery. Additionally non metallic strapping is available in many colors from the suppliers. With our need to recycle and separate all packaging, it is not economical to analyze or test all strapping to determine its composition. In addition, mixed colors have little or no market value for recycle strapping. STRAPPING COLOR MUST BE STANDARDIZED USING THE FOLLOWING: STEEL BLACK POLYESTER TRANSLUCENT GREEN POLYPROPYLENE TRANSLUCENT CLEAR The use of any other strapping requires approval from your GDLS representative. Many other GDLS facilities recommend polyester strapping due to its strength and recovery properties. Nylon has no color standard applied to it. We know of no process or program to effectively recycle nylon; Its cost is excessive, and its performance can be matched with polyester strapping. Friction sealing is recommended for all non metallic strapping, and metal clips or buckles are discouraged. Elimination of the metal clip for non metallic strapping reduces cost and effectively allows recycling without the potential of metal contamination. The sealing tools to perform this function are powered by either compressed air, electricity or battery. NOTE: Supplier is responsible for packaging performance test. Prototype and sample shipment is necessary. 13

15 Environmental Packaging Suggestions 6: PALLET UNITIZING METHODS Steel or plastic strapping and stretch wrap have been the acceptable method of securing cartons to a pallet. Our assembly plants are working to recycle all packaging materials; strapping and stretch wrap. As a supplier, you can assist our efforts by: Strapping Incorporate the standardized colors and strap sealing method recommended in the strapping section. Stretch film Use clear film; the absence of color maximizes recycling potential. Specify LDPE (low density Polyethylene) film. LDPE films are the most common, highest performing types of film and should be used. PVC film is not to be used. Wrap the palletized unit with only the required amount of film, minimizing waste. Your film or equipment supplier can assist you with the proper use of the material and equipment. Unitizing adhesives This special adhesive is the best environmental option, requiring no strapping or stretch film to be collected, processed or recycled. Many suppliers are using this concept, and it is widely accepted. Supplier benefits are: 1. Wrap time eliminated. 2. Equipment/floor space savings. 3. Load integrity, appearance. 4. Inspect/repack ease. 5. Unit load increased. Nothing stretches/moves. Possibility for reduction of corrugated material. 14

16 Environmental Packaging Suggestions 7: SPI PLASTIC RESIN CODES To facilitate the recycling of a product, its identity must be known. There are numerous types of plastics used for packaging which require a simple method of identification. GDLS C now requires the marking of the SPI (Society of Plastic Industry) code on all plastic products. The SPI code chart is shown below. All vacuum formed and injection molded plastic packaging material must be identified by this code. Plastic packaging components such as plugs, caps, and covers are to be marked with SPI codes. 15

17 Environmental Packaging Suggestions 8: WASTEFUL, EXCESSIVE, OR NON RECYCLABLE MATERIAL Packaging is required to serve many needs; part protection, transportation effectiveness, synchronous manufacturing, ergonomic and environmental concerns to name a few. GDLS C discourages the use of wasteful and/or excessive packaging. The challenge then is to meet the requirement by using the minimum amount of packaging, and no more. Overpackaging and wasteful just in case packaging is undesirable for both the supplier and the user. Each GDLS C supplier is expected to identify and correct such packaging on an ongoing basis. With reduction or elimination as the first priority, the hierarchy of waste elimination is: REDUCE REUSE RECYCLE To list every example of wasteful, excessive or non recyclable packaging would be too extensive. We have identified a few examples that have caused significant problems within our plants: Excessive, oversized corrugated which is partially filled or designed beyond the requirement. Excessive, oversized foam and plastic dunnage. Micro cellular foam wrap and bubble wrap. Plastic protective covers, caps, plugs, paint masks or spacers required in the manufacturing process but not required as a protective shipping device. Non recyclable packaging is that which has no economical system for removal of the packaging. Wax coated corrugated is a prime example of this type of packaging. Waxed or plastic coated corrugated and paper are prohibited because it is not recyclable. Plastic plugs, caps and protectors are extremely difficult to recycle due to oil and paint contamination, and the uncertainty of a resin type. Every effort should be made to eliminate plastic. If it cannot be eliminated, other substitute materials should be considered to assist the plant s recycling efforts: 1. Mold the SPI code into the part. The printed code identification will allow for effective recycling Clear LDPE plastics are preferred and can be effectively recycled. 2. Plastics should not be contaminated with paints and lubricants. 3. Replace the plastic with a paper substitute. Prior to shipment of material, remove all plastic caps, plugs, spacers, etc., if not required for packaging or shipping protection. 16

18 MATERIAL HANDLING GUIDELINES MANUAL Background: Back injuries result in approximately 50% of all industrial related injuries within the workforce. In turn, these injuries increase our losses associated with productivity, safety and quality. In order to reduce the costs associated with these losses, it is imperative that we improve the manual material handling of our packages. The following standards have been adopted from the research guidelines and principles designed to reduce the risk factors associated with back injuries. PACKAGING DIMENSIONS 1 Any package which may be manually handled should not exceed these standard dimensions (see below). This includes packages on skids (palletized loads) which are loaded by forklift, but manually loaded onto the skid by employees. 2 Large boxes, bins or waste cartons which are used to hold more than one part should not be higher that 32 inches from the floor, in order to allow easy accessibility to the inside of the package when reaching for the part. 17

19 MATERIAL HANDLING GUIDELINES MANUAL (continued) Acceptable Loads The weight of the package greatly influences the compressive forces placed on the back (intervertebral discs). The design of new packages should not allow excessive loads to be manually handled by employees. The guidelines below are based on manual material handling techniques which allow the package to be carried close to the body and will not require excessive bending or squatting. 1. Boxes, cases or cartons which are within the standard dimensions and do not have hand holds should not exceed 35 lbs. 2. The weight of the package should be clearly written on the box or on our standard label. (see Appendix B) The size of the text should fill the space provided and should be a minimum of 2.75 wide and 2.75 long. 3. The package should be designed in such a way that it will enhance mechanical movement and discourage and reduce the risk of injury. HANDHOLDS Handholds can increase the acceptable weight of load tolerance by 10%. The handholds reduce the vertical travel distance by 5 6 with each lift this reduces an employee s metabolic consumption by 11%. 4. Any box which is greater than 35 lbs in weight must have handholds constructed in the two opposite sides of the box. The acceptable load with handholds is 39 lbs. In order to reduce the mechanical stress placed on the hand while the carton is being carried, the hand hold should have the minimum dimensions as shown below: Length of Handhold; 5 Curvature or Width of Edge 1.25 minimum (Handhold / Hand Surface Contact) 18

20 MATERIAL HANDLING GUIDELINES MANUAL (continued) 1. The handholds should be located so that when the item is picked up it does not come in contact with the legs. More specifically, the handholds should be located slightly above the package s center of gravity. See the example below for correct placement of the handholds. 19

21 MATERIAL HANDLING GUIDELINES MECHANICAL When any item is deemed too heavy for manual material handling (approx 40 pounds & dependant of size) it must have provisions to be handled by a forklift or other mechanical means. This could include the provisions of skids on a crate, or the use of a pallet to provide adequate handling capability for a large corrugated box. When a crate longer than 94 inches is required it must have provisions for 4 way forklift entry. This will provide the ability to safely load the container lengthwise in a truck van when the container does not fit widthwise. When oversize items are shipped, the pallet must be larger than the part to ensure parts are not hanging out beyond the pallet providing damage opportunities and dangerous situations. 20

22 GENERAL DYNAMICS LAND SYSTEMS CANADA PALLETS When a wooden pallet is required for reasons of strength or durability the suggested size is 36 wide x 48 long. See attached drawing D Specialty designed pallets may be available for parts which do not fit on this size of pallet. Contact the GDLS C Handling/Packaging Representative at , if more information is required. The Handling /Packaging Representative has Preferred Pallet Suppliers who will extend GDLS C pricing onto their suppliers. Contacts available on request. SPECIFICATIONS: UNIVERSAL PALLET D Solid top decks and end boards are 1 x 6, (rough cut, random width preferred). 2. All bottom deck boards are 1 x 6 (rough cut, random width preferred). 3. Runners are 2 x 4 (nominal). 4. All lumber must be Heat Treated hardwood (required). 5. Pallet must be assembled using 2 1/2 min. spiral nails. 6. D must be stenciled in 1/2 min. high characters centered over each outside runner. 21

23 GENERAL DYNAMICS LAND SYSTEMS CANADA PALLETS 1. All lumber should be hardwood. 2. Standard sizes: 36 x 40, 40 x 48, other sizes are acceptable. 3. Items should fit within the perimeter of the pallet without overhang. 4. No visible bark permitted on any lumber. 5. Each deck board fastened with a minimum of 6 spiral nails or screws. 6. Two way or four way entry pallets are acceptable. 7. Maximum allowed dimension of knots is 1 1/2, but not over ½ the width of a board. WING PALLET DECKBOARD EXTENSIONS PERMITTED 1 1/2 MAXIMUM GAP BETWEEN DECKBOARDS 3/4" MINIMUM THICKNESS DECKBOARDS 4 WAY LIFT CUTOUTS ARE OPTIONAL ALL DECKBOARDS FLUSH ON BOTH ENDS WOOD MUST BE HT OR KD. APPLICABLE STAMP IS REQUIRED 3 STRINGERS MINIMUM MUST BE AT LEAST 2 X 4 S 3 BOTTOM SKID BOARDS MINIMUM SUPPLIER PALLET MINIMUM REQUIREMENTS 22

24 HAZARDOUS MATERIALS PACKAGING REQUIREMENTS: Hazardous materials must be packaged and shipped in accordance with the appropriate Department of Transportation Regulations using Performance Oriented Packaging Standards when required. Ensure the Material Safety Data Sheet (MSDS) documents are accompanied with each shipment. Hazardous Material is permitted on GDLS Facilities after it has been approved by Supply Chain Management and the Hazardous Materials Control Committee. The sending in of samples or bringing of unauthorized hazardous materials into a GDLS Facility is forbidden. Strict compliance to this requirement is mandatory. 23