Packaging Directive After Sales/Spare Parts MAN Corporate Design
MAN Packaging Directive for After Sales/Spare Parts is the basis for the Genuine Spare Parts packages being in the proper state. The directive always applies in conjunction with MTB logistics standard M3399 and the logistics agreements concluded between MAN and the supplier. MAN Corporate Design
Page 3 Content Design of cardboard packaging 4 Basic component and placement 4 Wallpaper pattern 5 Printing and procurement sources 6 Labels 7 Pallets 17 Strapping and mesh boxes 18 Use of adhesive tapes 19 General requirements concerning packaging 20 Regulations and standards 21 Labelling of round containers 10 Labelling of hazardous products 12 Labelling of other products requiring special handling 14 Common-rail parts 14 ESD - electrostatic discharge 16 Fragile goods (e.g. panes of glass) 16
Page 4 Design of cardboard packaging Basic component and placement The basis of the design is the following basic component: the logo Originalteil, Genuine Part consists of the MAN product logo, the text Originalteil, Genuine Part and the NEOPLAN logo. The protected space is an element of the logo: no graphic elements may be located here and no format boundaries may run into it. It is a rectangle defined by the N. The basic component is printed centrally on (at least) two of the sides with the biggest surface area. There are four standard sizes available for this purpose. These are used as follows. Size A (65 mm x 74 mm) for cartons from 10 to 25 cm in height Size B (180 mm x 164 mm) for cartons from 25 to 50 cm in height Size C (260 mm x 237mm) for cartons from 50 to 100 cm in height Size D (400 mm x 364 mm) for cartons more than 100 cm in height Example: 180 mm (scale 1:2)
Page 5 Design of cardboard packaging Wallpaper pattern Alignment line The wallpaper pattern is used for cardboard packaging made from single-wall corrugated cardboard with walls of Type E, F and G (as per DIN 55468) and for all cardboard packaging made from paperboard (as per DIN 19303). To create this pattern, the basic component is arranged in a staggered form to a wallpaper pattern and the entire pattern rotated 45 to the left. Distance: height of The basic component comes in two sizes for the wallpaper pattern. Basic component I: 26 mm x 24 mm Basic component II: 16 mm x 15 mm Basic component II may only be used in exceptional cases (e.g. cartons smaller that 50 mm wide x 50 mm high x 23 mm deep) 26mm
Page 6 Design of cardboard packaging Printing and procurement sources Both the basic component and the wallpaper pattern are printed in a single colour (black). This means that the basic brown or grey colour of the respective cardboard packaging is retained. Caution! No additional third-party information concerning the manufacturer, designation or ID no. may be printed on the cardboard packaging. Please note that the eps logo provided must be used for every type of implementation. You can request the logo and the wallpaper pattern from: Tobias.Martin@man.eu Cardboard packaging can be procured on the open market as well as via the mail account below. The quality and design of the cardboard packaging must meet MAN requirements. MAN requirements can be obtained via the central mail account VPL-DAH@de.man-mn.com. In order to ensure that deliveries arrive on time, please initiate procurement at least 14 work days prior to the date of packing.
Page 7 Labels Label sizes Labels shall be used to identify the contents of packages and are available in four different sizes. The basic colour of the label and the fields on the label is always white. The printing is black. Label A: 35 mm wide x 25 mm high Label B: 50 mm wide x 36 mm high Label C: 77 mm wide x 56 mm high Label D: 160 mm wide x 90 mm high Types of label The label is used to convey all product-specific information. There are various types of label: n Labels that are printed directly onto the carton. When large batch sizes are packed, the label is printed directly onto the packing material. The size of the label may be adjusted to suit the packaging material. n Labels that are used as stickers n Labels that are produced on an in-house basis. These labels can be ordered from MAN via the central mail account by writing to VVP.Dachau@de.man-mn.com. In order to ensure that deliveries arrive on time, please initiate procurement at least 14 work days prior to the date of packing. Fonts MAN s corporate font is MAN Global. This font was specially developed for MAN on the basis of Helvetica and is commercially available: Tel.: +49 40 606050, info@urwpp.de Agencies that already have HelveticaNew from Linotype may continue using it. (You can find more detailed information on the MAN Brand Portal: www.man-brandportal.eu) Please note: MAN fonts are to be used exclusively for orders from the MAN Group. Use for any other purposes is not permitted. Label A: 35 mm wide x 25 mm high
Page 8 Labels Label B: 50 mm breit x 36 mm hoch 9999999999 Label C: 77 mm breit x 56 mm hoch The label contains the following data: n Logo Originalteil Genuine Part n The quantity of parts contained in the package n Packing date or expiry date (e.g. for adhesives, oils and so on) The packing or expiry date must be identified as such. Packed on: xx.xx.xx or Use by: xx.xx.xx n MAN part no. n Part no. shown in bar code 128 Type B n Country of manufacture n Batch no. Caution! No additional third-party information concerning the manufacturer, designation or ID no. may be printed on the carton. Positioning n As a basic principle, the label must be affixed to the front side of the carton. If the label cannot be affixed there, it must be affixed at some other clearly visible point. n The label may only be affixed to packages for MAN Truck & Bus AG products that are sold by MAN. n Moreover, no additional, third-party labelsmay be affixed to the package. For special regulations, please see the section entitled Labelling of packages containing hazardous substances. n The label used must be suitable for the size of the carton see p. 7 Label size.
Page 9 Labels Label D: 160 mm breit x 90 mm hoch
Page 10 Labelling of round containers For round containers such as cans, bottles, canisters, barrels and so on there is a uniform packaging strip or band with the building block printed on it; basic colour 100% anthracite, printing 40% black. The height of the band depends on the overall height of the container; the band must always be one fifth of the overall height. Colour definition of anthracite: CMYK 63 /32/14/76 Pantone 7546C RAL 5008 RGB 48/60/73 The typography and layout of the part no. label for round containers is defined on the following pages.
Page 11 Labelling of round containers
Page 12 Labelling of hazardous products In the case of chemical products with properties that endanger health and the environment, the package must display the stipulated information in accordance with the respectively applicable national and EU directives. Amongst other information, the following is mandatory: 1. Chemical identification of the hazardous substance or substances contained in the product. 2. The hazard pictograms must comply with the new CLP regulations. The hazard pictograms show a black symbol on a white background in a red-framed square set at a point (Annexe V of the CLP regulation). Every hazard pictogram must be at least 1 cm 2 big and cover at least one tenth of the surface area of the marking. 3. Hazard statements 4. Precautionary statements 5. Name, complete address and telephone no. of the manufacturer, the importer or the retail company. In the case of manufacturers located outside the European Union, the name and full address of the company or person importing the substance into the EU or re-introducing it onto the market. 6. Depending on the hazard category, the corresponding signal word must be used.
Page 13 Labelling of hazardous products 7. In addition, the following must be stated on aerosol dispensers (spray cans): 7.1. Pressurized container. Protect from sunlight. Do not expose to temperatures exceeding 50 C. Do not pierce or burn, even after use. 7.2 If aerosol dispensers (spray cans) contain extremely flammable, highly flammable or flammable substances or preparations, they must in addition be labelled with the precautionary statements. Do not spray on an open flame or other ignition source. Keep away from heat/sparks/open flames/hot surfaces. No smoking. Keep out of reach of children., the hazard pictogram and the indication of the danger as well as the hazard statements corresponding to the category of the substance or preparation, including propellant, contained in the aerosol dispenser (spray can). The dimensions of the labelling depend on the volume contained by the packaging and must be as follows. n Up to 0.25 litres: a format of a suitable size n Between 0.25 and 3.0 litres: a format of at least 52 x 74 mm n Between 3.0 and 50 litres: a format of at least 74 x 105 mm n Between 50 and 500 litres: a format of at least 105 x 148 mm n More than 500 litres: a format of at least 148 x 210 mm
Page 14 Labelling of other products requiring special handling 9999999999 Common-rail parts The stringent requirements with respect to cleanliness and purity necessitate a specific handling of common-rail parts with regard to how they are treated, packed and labelled. (The in-house standard applying at MAN is M 3360.) All common-rail parts must be n packed individually in welded plastic foil. n packed in a carton. n In addition to the standard markings, the carton must in addition be labelled with the words Common Rail. n As a basic principle, this special information shall be affixed below the label.
Page 15 Labelling of other products requiring special handling
Page 16 Labelling of other products requiring special handling ESD - electrostatic discharge Electronic systems and components exposed to the risk of damage due to the build-up of electrostatic charges and the corresponding discharges require special handling with regard to how they are treated, packaged and labelled as per DIN EN 61340-5-1. (The in-house standard applying at MAN is M3431.) The systems and components that fall under this rule are identified correspondingly in the definition documents. To detect instances of unauthorised opening, the packaging is to be sealed with the adhesive security tape bearing the warning No returns. Procurement source: please see the section entitled Use of adhesive tapes Fragile goods (e.g. panes of glass) Fragile goods must always be packed in such a manner as to preclude any damage under normal conditions of storage and handling. As a basic principle, panes must be provided with intermediate layers (cork spacers, polystyrene corner blocks, etc.), packed vertically in rigid packaging (e.g. a wooden frame with a plastic foil covering) and transported in a vertical position. In addition, the packaging must be labelled with a Fragile pictogram. Note: In the case of ribbed panes, it must be ensured that no stickers (e.g. self-adhesive cork spacers) are affixed to the ribbed glass surface (adhesive residue!). If glass panes are packed individually in a single carton, red adhesive tape always has to be applied and in addition a Tilt Watch label affixed to the carton, if so agreed.
Page 17 Pallets Pallets n Maximum dimensions of non-returnable pallets with cargo 2,500 mm x 1,200 mm x 1,700 mm (LxWxH) n Cardboard packaging may not protrude over the edge of the pallet. n The maximum overall height of a packing unit (cardboard packaging and pallet) may not exceed 1,700 mm. n In order to avoid damage to the bottom layer of cartons, the total weight (stackable load) must be taken into consideration when stacking. n Every packing unit must be labelled with the corresponding part no., quantity of parts and supplier as laid down in VDA Recommendation 4902. n All wood used (non-returnable pallets, crates, weighting, etc.) must be treated and marked in accordance with the IPPC standard. n The gross weight of a small load carrier ( KLT ) may not exceed 20 kg. Small load carrier Below are the maximum quantities of small load carriers permitted on a non-returnable pallet or Europallet (1,200 x 800 mm). These quantities may not be exceeded. Designation MAN - Part no. Dimensions in mm Small load carrier (L x B x H) Europallet KLT 3214 09.84019-0027 300 x 200 x 147,5 96 KLT 3215 09.84019-0527 300 x 200 x 147,5 96 KLT 4314 09.84019-0020 400 x 300 x 147,5 48 KLT 4315 09.84019-0520 400 x 300 x 147,5 48 KLT 4328 09.84019-0021 400 x 300 x 280 24 KLT 4329 09.84019-0521 400 x 300 x 280 24 KLT 6428 09.84019-0022 600 x 400 x 280 12 KLT 6429 09.84019-0522 600 x 400 x 280 12
Page 18 Strapping and mesh boxes Strapping n Every single carton with a gross weight (spare part plus carton) of more than 5 kg must always be strapped at least twice, at its left and right extremities, with a plastic strap. n Stacks of cartons must in addition be secured against sliding around the pallet or tipping over by at least two plastic straps, at their left and right extremes (see illustrations). n Edge guards must also be inserted between the carton and the strap running around the circumference. n Small load containers must be secured against sliding by means of plastic straps and/or stretch foil. n Heavy parts (e.g. engines, gearboxes, etc.) must be secured by means of steel straps. Wooden crates containing heavy parts must be additionally secured on the outside with steel straps. n All small load container units with the basic dimensions of 1,200 x 800 mm delivered on pallets must be covered by means of Cover A 1208 (VDA 4500). Mesh boxes n As a basic principle, re-usable containers should be employed. The empties required are to be obtained from the main supply plants via the container-management system (MN-CM). n No damaged mesh boxes may be used. n Goods delivered in mesh boxes may not protrude out of the boxes or over their uppermost edge. n The weight restrictions applying to load carriers must be observed. n The quantity of stipulated packages per load carrier may not be changed without prior consultation.
Page 19 Use of adhesive tapes As a basic principle, all cartons must be properly sealed by means of one of the following adhesive tapes. In accordance with the MAN logistics main data sheet, the packaging of individual parts for customers shall employ the MAN adhesive tape (Part no. 09.81008-1000) and red adhesive tape (Part no. 09.81008-1002). The controlunit adhesive tape (Part no. 04.93300-9268) is mandatory for control units. Printed on this adhesive security tape is No returns. Red adhesive tape must always be affixed to spare parts made from glass or parts containing glass. In consultation with MAN, Dept. PPLI, all other packaging units may also be sealed with transparent adhesive tape. Procurement sources: n MAN adhesive tape and red adhesive tape: these can be procured on the open market. The quality and design of the tape must meet MAN requirements. MAN requirements can be obtained via the mail account described below. Alternatively, tape can also be procured directly from the certified MAN supplier JABand GmbH, Stockacherstr. 9/2, 81243 Munich Tel. +49 89 82 91 53 24 For reasons of trademark protection, MAN reserves the right to check the quantities obtained from the JABand company. n Adhesive tape for the control unit (adhesive security tape) and the supplementary label No returns are to be obtained exclusively directly from MAN, Dept. PPLI. Types of adhesive tape: Written procurement must be initiated at MAN via the central mail account of Goods Receipt in Dachau. The address is VVP.Dachau@de.man-mn.com. In order to ensure that deliveries arrive on time, please initiate procurement at least 14 work days prior to the date of packing. MAN adhesive tape Part no. 09.81008-1000 Red adhesive tape Part no. 09.81008-1002 Adhesive tape for control unit Part no. 04.93300-9268 (adhesive security tape)
Page 20 General requirements concerning packaging MAN s packaging matrix serves as a tool for selecting and designing the packaging. The following points must also be observed: Selection of cartons: The quality of the carton must provide adequate stability for the part to be packed and withstand the stresses to which it is exposed during transport, handling and storing ( THS exposure ). When selecting cartons, their stacking capability must also be taken into account (DIN 55468 ff. and DIN 55428 ff.). Interior cushioning: The cushioning is decisive for the quality of the overall packaging unit. The cushioning elements should immobilise the packed item in its carton and at the same time help to improve the carton s stacking capability. All non-returnable packaging must be made from environmentally friendly, recyclable materials that are accepted everywhere for recycling. Loose filler material must be dispensed with. A list of permitted materials can be found in the standard M 3338. Corrosion protection: Corrosion-prone parts must be protected for the duration of their transport and storage. The following methods may be employed. n VCI materials n Dessicants n Corrosion protection by means of coating, e.g. with wax or oil n Combinations of the above MAN standards M 3069 ff. and M 3167 are to be observed.
Page 21 Regulations and standards This packaging directive is based on the following standards and regulations. DIN 55428 ff. DIN 55428 ff. DIN 19303 DIN EN 61340-5-1 M 3069 ff M 3167 M 3338 M 3360 M 3399 M 3431 VDA 4902 VDA 4500 Packaging materials - Corrugated fibreboard Packaging materials - Solid fibreboard Paperboard - terms and grades Electrostatics - Protection of electronic devices from electrostatic phenomena Temporary protection against corrosion, corrosion-protection system Conservation and packing of engine parts with VCI materials for transport Packaging Directive Parts with special requirements in terms of cleanliness MAN Truck & Bus AG logistics standard Guideline for the prevention of damage to electronic systems by electrostatic discharge(esd) Goods tags Small load container (KLT) system Aerosol packaging regulation REACH-/CLP regulation Packaging matrix (request directly from: Tobias.Martin@man.eu ISPM standard 15/ IPPC standard