Design guideline for pallets within Ericsson

Transcription

1 DESIGN RULES 1 (1) Design guideline for pallets within Ericsson Summary This document describes design guidelines that shall be considered when pallets are designed within Ericsson. General This document is based on input from suppliers, legislation, regulations, international standards, and Ericsson requirements for packaging material. Definitions Definitions and terms apply to most pallet designs. Deck boards/ Deck sheet Blocks Vertical / horizontal entry Bottom deck boards/runners Stringers

2 DESIGN RULES 2 (2) Contents 1 Design considerations General requirements... 5 Pallet size... 5 Phytosanitary Treatment, ISPM way handling Designing a pallet Dimensions Pallet standard dimensions Vertical clearance for truck handling Horizontal clearance for truck handling Warehousing Pallet inbound deliveries Warehouse stacking Warehouse racking Safety factor Nailing Blocks and skids/runners Chip blocks Plywood blocks Solid wooden blocks or runners Metal blocks Composite blocks Material in deck, stringers, and bottom deck/runners Wood Plywood Plastic and paper pallets Pallet product number marking Design options Edge board profiles Corner profiles Full deck or deck boards Deck holes and guides Deck cover Strap slots Pallet verification Documentation Pallet product numbers Pallet product numbers with suffix Erimate declaration drawing Nailing Specification for pallets, 1301-RTK 531 Uen... 17

3 DESIGN RULES 3 (3) Measurement tolerance General information in PiWin References Revision history... 19

4 DESIGN RULES 4 (4) 1 Design considerations When designing pallets many things must be taken in to consideration. Some examples are: Pallets must be durable and withstand the strain from rough handling and still protect the products that it carries. The pallet must be as light as possible to minimize/optimize freight costs. It must comply with standard transport and warehouse dimensions to minimize/optimize freight, storage, and handling costs. Environmental impact shall be considered when designing the pallet, both regarding material choices and legal requirements. Consideration shall be taken to ergonomic aspects and handling in production environments. The technical design of the pallet can differ depending on intended usage. Different designs of the pallet must be considered. See examples of different designs below. 600x800mm rib pallet 1200x800mm rib pallet Pallet with options Deck sheet pallet

5 DESIGN RULES 5 (5) 2 General requirements Some requirements are described in the General Requirements for Packaging Material Design, 1056-CSX , [Ref 1]. These are specified below. Pallet size To optimize transport and storage the pallets must comply or divide with standard size of 1200 x 800 mm. Exceptions are only permitted where it cannot be achieved cost effectively. See req. tag 032 in CSX Phytosanitary Treatment, ISPM 15 Pallets manufactured out of natural wood or have parts of natural wood must be processed and approved according to ISPM-15 regulations. See req. tag 006/066 in CSX Additional information regarding ISPM 15 Marking must be complete and fully visible. Incomplete or not readable markings according to the right picture below are not accepted and will not be approved in the distribution flows. Correct marking Incomplete marking 4-way handling 4-way handling of pallets is needed to facilitate good handling in all transport flows. Exemptions from this requirement may occur depending on vertical and/or horizontal clearance, see chapter and See req. tag 033 in CSX

6 DESIGN RULES 6 (6) 3 Designing a pallet 3.1 Dimensions Pallet dimensions are very important. They should comply with standard dimensions within the logistic flow. Dimensions and limitations on trucks, containers, warehouse storage, forklifts, etc. must be considered. Pallet dimensions also differ depending on where you are in the world and what means of transportation are used Pallet standard dimensions Below are the most commonly used pallet sizes within Ericsson. 1200x800 mm, EUR standard size 600x800 mm, EUR standard half size 1160x760 mm, Container pallet Vertical clearance for truck handling The minimum clearance for vertical entry on pallets is 90 mm. This clearance is needed in at least 2-ways of entering the pallet with forklift Horizontal clearance for truck handling The minimal horizontal clearance inside outer pallet block for entry with forklift is 580 mm. This clearance is needed in at least 2-ways of entering the pallet.

7 DESIGN RULES 7 (7) 3.2 Warehousing Pallet inbound deliveries To minimize the inbound delivery volume of pallets, you have the possibility to flip every other pallet upside down as shown in below illustration. This will reduce the volume with approx. 35% compared with standard one on one stacking. The disadvantage with this solution is that it needs manual handling in production to flip back every other pallet to normal side Warehouse stacking Pallets shall be designed to facilitate stacking, both regarding interfaces between pallet stacked on pallet, and pallet stacked on top of product. Example of pallet stacked on pallet.

8 DESIGN RULES 8 (8) Example of stacked pallets with inclined blocks and bottom runners that permit pre-assembly of edge board or metal frames on the pallet top deck. Illustration of inclined blocks and bottom runner permitting stacked pallet to fit inside the edge board frame on the lower pallet. Example of pallet stacked on product box Ericsson /// Ericsson ///

9 DESIGN RULES 9 (9) Warehouse racking Pallets with standard dimensions (1200x800/1000) shall be designed for racking. Racking is when a pallet is stored in, for example high capacity storage shelves with two parallel beams. See illustration below. Pallet must be strong enough and not to bend more than allowed according to ISO standard described in the 8/ /FEA , Test specification for pallets. See ref 2 in this document. This is to facilitate effective handling in warehouses. Exceptions are made from this based on special usage or odd sizes pallets/products. Storage rack beams Safety factor A safety factor of at least 2.0 based on the pallets maximum work load is mandatory when designing a pallet. Maximum work load = Highest product weight the pallet is designed for. Calculation example: Maximum work load x safety factor, 100 kg x 2 = 200 kg The pallet shall hold for at least 200kg weight when tested. See more about testing in section 5, pallet verification. 3.3 Nailing Using correct nail type and nail dimension is very important to get a solid and strong joint between boards and blocks. The separate document Nailing specification for pallets, 1301-RTK 531 Uen [Ref 5], describes how nailing of pallet must be performed for wood/plywood pallets designed for or by Ericsson.

10 DESIGN RULES 10 (10) 3.4 Blocks and skids/runners Pallets with blocks are the most used design within Ericsson. This is to facilitate 4-way handling in the distribution flows. There are also pallet designs with skids or runners, see pallet illustration above. These designs are not commonly used within Ericsson Chip blocks Chip blocks are produced of wooden chip glued together under high pressure. The blocks shall be manufactured with a density of at least 600kg/m3. The density shall be specified on the 1301-drawing. Chip blocks are classified as non-solid blocks and does not require ISPM-15 treatment. The most used standard sizes of chip blocks are 75x75x78 mm and 95x95x78 mm, but many other standard sizes are also available from the suppliers. Commonly used on the European markets Plywood blocks Plywood blocks are produced of waste material from other plywood products. They can be manufactured in any size. The blocks are made from sheets of plywood that are joined either with nails or with glued under pressure. Commonly used in the Asian markets Solid wooden blocks or runners Solid wooden blocks are made from raw wood and can be produced in any shape and size. This type of block needs treatment according to ISPM-15. There are also some risks to consider when using solid wood block.

11 DESIGN RULES 11 (11) The surrounding climate conditions can affect natural wood. Wet and dry conditions can for example cause varieties in measures, weight, and durability Dry conditions can result in cracks and nails losing their grip. Moisture can cause the wood to mold or change color. Solid wooden blocks are mostly used in American markets (North, South and Latin America) Metal blocks Metal block can be used in a pallet designs solutions. They are available in most regions in the world. Metal blocks are used only together with plywood boards. Most common are round blocks and they are available in different sizes. These blocks are very durable, but also more expensive than other block types. There are also recycling cost at the end user to consider with these solutions. Metal blocks may not be used unless special requirements Composite blocks The composite blocks are produced from industrial waste material such as polyethylene plastics, cardboard and paper fiber. The main material is plastic 80%, which is mixed with about 20% of paper or wooden fibers. This type of block is not globally available. These blocks are more durable than chip or plywood block but also more expensive. Composite blocks may not be used unless special requirements.

12 DESIGN RULES 12 (12) 3.5 Material in deck, stringers, and bottom deck/runners All wood based material use in pallet designs must follow the document, Ericsson s standardized framework for pallet design, CNX /1 Uen [Ref 6] Wood Most common dimensions of wood boards used in pallets are 16, 19, or 22 mm. Material dimensions shall be specified on the 1301-drawing of the pallet. Minimum quality classification for wood material in European manufactured pallets shall be according to Sawn timber - Appearance grading of softwoods, EN [Ref 3] classification G4-3. Classification shall be specified on 1301-drawing. Raw wood shall be treated and marked according to ISPM 15. Wane edges on wood boards are allowed but shall be kept to a minimum. Bark on the edges is not allowed Plywood The quality and properties of plywood can differ depending on where you are in the world. This is due to the quality of the raw wooden material that the plywood is produced from. Consideration must be taken regarding this when choosing plywood dimensions to get the wanted strength of the pallet. Commonly used thickness dimensions of plywood boards for pallets are 8, 12, 15, 18 and 22 mm. The material quality/classification and strength shall be specified on the drawing of the pallet. See document, Plywood test method and specification, [Ref 4] Plastic and paper pallets Plastic and paper pallets shall not be used in the Ericsson inbound flow or outbound flow to customer. They may be used for controlled material flows internally within or between Ericsson sites.

13 DESIGN RULES 13 (13) 3.6 Pallet product number marking A product number can be placed on a pallet for easy identification. This is done either by printing or heat marking. The pallet 1301-drawing shows if marking shall be applied on the pallet. 4 Design options Pallets can be designed with special features or accessories to add extra functions. Most often are these functions designed as support to other parts of the packing material such as fitments or frames. 4.1 Edge board profiles Different sizes of edge board profiles can be used on pallets. Most common are sizes between mm with a thickness up to 5 mm. The profiles are normally attached to the pallet with a staple gun. Commonly used to support to fitments or corrugated frames.

14 DESIGN RULES 14 (14) 4.2 Corner profiles These profiles can be made of steel, plastic, or edge board. Same function as for above edge board profiles. 4.3 Full deck or deck boards Different deck boards can be chosen. Sizes, material, and placement of the boards can be tailor-made to maximize the function needed. A full deck can also be an option, often made of plywood as shown below. Below illustration shows two examples with double side-deck boards that were used to support a wide fitment. 4.4 Deck holes and guides These options can be used when exact fixation of fitments is important, for instance in automatic packaging lines.

15 DESIGN RULES 15 (15) 4.5 Deck cover When using a rib pallet, it is sometimes necessary to place a cover on top of the deck boards to protect the products from dirt or water splash coming up from underneath the pallet. This cover can for example be a water resistant corrugated sheet that is stitched to the pallet. 4.6 Strap slots These slots are cut-outs made in the pallet deck as guidance to place the strapping in the correct place. The function of these slots is also to protect the strap from wear in the transport handling flow. Deck cover Strap slots 5 Pallet verification Testing is needed to verify the performance of a new pallet design. Different tests shall be done to verify that the pallet design meets the specified work load and safety factor. Test shall be performed according to Test specification for pallets, 8/ /FEA , [Ref 2]. Detailed verification report shall be presented to Ericsson after performed test. If a similar pallet design has been tested previously, the test result can be used and referred to.

16 DESIGN RULES 16 (16) 6 Documentation 6.1 Pallet product numbers When designing a new pallet, the product number series RTK 531 xx/* shall be used Pallet product numbers with suffix If a specific pallet design is manufactured in different regions of the world, different material is most likely used due to material availability. In this scenario a new product number and a new Erimate declaration is needed. Same general product number can be used but with different suffix numbers. See example below: RTK /1 = Wooden pallet with chip blocks (European market) RTK /2 = Plywood pallet with plywood blocks (Asian market) 6.2 Erimate declaration A detailed material declaration shall be made for pallets. All material in the pallet shall be specified in the declaration. Wood Plywood, (including urea formaldehyde and formaldehyde) Cardboard Plastic Metal, (incl. nails) drawing A specific1301-drawing template for pallet design must be used, see example drawing below. This template is included in the 1301-Collection and can be downloaded from the Package Material Developments Extranet homepage.

17 DESIGN RULES 17 (17) Note: pos 8 in 1301-template describing nails does not need to be filled in. It refers to the document Nailing specification for pallets, 1301-RTK 531. Change pos-number if needed Nailing Specification for pallets, 1301-RTK 531 Uen The document Nailing Specification for pallets, 1301-RTK 531 Uen must be added in the pallets in PiWin. as a part of the pallet specification together with the pallet drawing.

18 DESIGN RULES 18 (18) Measurement tolerance Tolerances shall be specified in the 1301-drawing of the pallet according to ISO 2768-V unless otherwise stated on drawing. 6.4 General information in PiWin It is important to specify the pallet dimensions (DxWxH) correct in PiWin. These dimensions are used in the Supply organizations to plan the loading of trucks. The following rule shall be applied to set the dimension. Design rules regarding pallet dimensions in stored PiWin - The depth dimension equals the forklift entry direction - The width dimension equals side entry direction - The height dimension equals bottom side to top side Depth Width Heigth Forklift entry direction

19 DESIGN RULES 19 (19) 7 References [Ref 1] [Ref 2] General Requirements for Packaging Material Design, 1056-CSX Uen Test specification for pallets, 8/ /FEA Uen [Ref 3] Sawn timber - Appearance grading of softwoods, SS-EN [Ref 4] [Ref 5] Plywood test method and specification, Uen Nailing specification for pallets, 1301-RTK 531 Uen [Ref 6] Ericsson s standardized framework for pallet design, CNX /1 Uen 8 Revision history Document revision A to B includes the following changes. Chapter 1: text added about different technical pallet designs. Chapter 2: General Requirements has its own chapter. Chapter 3.1.1: container pallet 1160x760 mm added. Chapter 3.2.1: information about pallet inbound deliveries added. Chapter 3.3: information regarding nails and nailing process has moved to a new document, Nailing specification for pallets, 1301-RTK 531 Uen. Chapter 3.5: information added regarding new document Ericsson s standardized framework for pallet design, CNX /1 Uen [Ref 6]. Chapter 3.5.1: text updated about wood material quality classification. Chapter 3.5.2: information added regarding document Plywood test method and specification, [Ref 4]. Chapter 3.6: new chapter regarding pallet marking. Chapter 4: new chapter describing pallet design options. Chapter 5: text updated

20 DESIGN RULES 20 (20) Chapter 6.3: information regarding new 1301-drawing template for pallets. Chapter 6.3: picture updated to new 1301-drawing template. Chapter 6.3.1: information added regarding that the new Nailing specification 1301-RTK 531 Uen shall be added to pallets in PiWin. Chapter 6.3.2: tolerance class changed from ISO 2768-C to 2768-V. Chapter 7: Ref 3, 4, 5, 6 added. Chapter 8: Revision history added.