YAOM-PE-S12-015W

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    Yazaki North Ameri ca, Inc., 6801 Haggerty Road, Canton, MI 48187 734-983-1000 1 of 24

    YAZAKINORTHAMERICA Rev. 2.1WI No.:YAOM-PE-S12-015W Doc. YAOM-PE-S12-015W

    Component Supplier Packaging Guideline forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    Component Supplier Packaging Guideline

    for Standard Parts

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    YAZAKINORTHAMERICA Rev. 2.1WI No.:YAOM-PE-S12-015W Doc. YAOM-PE-S12-015W

    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    TABLE OF CONTENTS pg. 2

    1.0 SCOPE pg. 3

    2.0 ALLOWABLE CARTON DIMENSIONS pg. 42.1 Allowable Dimensions & Minimum Board Strengths pgs. 4, 5

    2.2 Bulk Cartons pg. 6

    2.3 Cartons Loading Diagrams pg. 6

    3.0 GENERAL CARTON CONSTRUCTION REQUIREMENTS pg. 73.1 Design pgs. 7, 8

    3.2 Carton Corner Posts pgs. 9, 10

    4.0 CARTON UTILIZATION REQUIREMENT pg. 10

    5.0 PALLET CONSTRUCTION pg. 125.1 Pallet Dimensions pg. 12

    5.2 Materials & Construction pgs. 12-14

    6.0 PALLETIZATION pg. 14

    6.1 General Requirements pg. 146.2 Stretch Wrap pg. 14

    6.3 Banding pg. 15

    6.4 Palletization of Cartons on Pallet pgs. 15, 16

    7.0 SUPPLIER TEST SHIPMENTS pg. 177.1 Test Shipment Reasons pg. 17

    8.0 SHIPMENT DAMAGE pg. 178.1 Damage Documentation and Resolution pg. 17

    9.0 LABELING pg.18

    9.1 Carton Labeling pg.189.2 Mixed Pallet Loads pgs. 18-21

    9.3 Master & Mixed Loads: General Info pg. 22,23

    10.0 ENVIRONMENTAL POLICY AND SOCS pg. 24

    11.0 PACKAGING QUESTIONS & ISSUES pg. 24

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    YAZAKINORTHAMERICA Rev. 2.1WI No.:YAOM-PE-S12-015W Doc. YAOM-PE-S12-015W

    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    1.0 SCOPE

    The Yazaki Component Supplier Packaging Guideline for Standard Parts outlines theminimum requirements for packaging systems of the following component families:

    o Tape / Foamo Clips / Fastenerso Nuts / Bolts / Screwso Connectorso Relayso Grommetso Some Shields & Brackets

    Standard Parts are hereby defined as: parts which are small and/or uniform inconfiguration which will fit into a pre-determined set of hand-held/human moveable

    carton dimensions.

    These minimum requirements shall be met by all component suppliers shipping standardparts to Yazaki North America. (Non-Standard part packaging requirements are discussed

    in Yazakis Component Supplier Packaging Guideline for Non-Standard Parts.)

    The packaging systems contained within this document will be used primarily in seacontainers (40, 40 High Cube, and 45) and shipped overseas to Yazaki manufacturing

    locations throughout the world. Component Supplier packaging must be robust so that itwithstand the rigors of extended overseas transportation (30+ days in transit) through

    warm/humid climates while also fully utilizing trailer and sea container space to

    minimize transportation costs.

    It is ultimately the Component Suppliers responsibility to ensure that their parts arriveat the end Yazaki manufacturing location undamaged. Suppliers must use packagingthat withstands the various dynamics of all transportation methods for land, air and

    sea.

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    YAZAKINORTHAMERICA Rev. 2.1WI No.:YAOM-PE-S12-015W Doc. YAOM-PE-S12-015W

    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    (L) (W) (H)

    11 1/4 x 6 x 5 SW SW DW SW SW SW

    12 x 11 1/4 x 5 SW SW DW SW SW SW

    12 x 11 1/4 x 10 SW SW DW SW SW SW SW

    22 1/2 x 12 x 5 SW SW SW SW SW

    22 1/2 x 12 x 10 SW SW SW SW SW

    24 x 11 1/4 x 10 SW SW SW SW SW

    24 x 22 1/2 x 10 SW SW DW SW

    24 x 22 1/2 x 15 SW SW DW SW

    48 x 15 x 10 DW DW

    48 x 15 x 15 DW DW

    48 x 22 1/2 x 10 DW DW

    48 x 22 1/2 x 15 DW DW

    48 x 22 1/2 x 20 DW DW

    ? x 45 x ? DW DW

    45 x 45 x ? DW

    24 1/2 x 24 1/2 x ? SW

    X

    CARTON SIZES & MINIMUM CARDBOARD MATERIAL REQUIREMENT

    STANDARD

    ITEMS

    STANDARD &

    NON-STANDARD

    ITEMS

    NON-STANDARD

    ITEMS

    Non

    Standard

    Packaging

    StandardPack

    aging

    CARTON NOT APPLI CABLE

    TerminalReels

    Relays&Busbars

    Nuts/Bolts/Screws

    MetalandPlastic

    Clips&Fasteneers

    RubberGrommets

    (Std.

    &NonStd.)

    AdhesiveTape/

    FoamTape

    ConvoluteTubing

    WireSpools/

    LiquidJugs

    Shields/Brackets

    (Std.

    &NonStd.)

    PlasticConnectorsCarton Size - OD

    (Outer Dimensions)

    + 0 / -0.5"

    (in inches)

    48x45WoodenPallet(+0/-0.5")

    Bulk

    Hand-Held

    Edge Crush Test

    (lbs/inch)

    Corrugated Board

    Material

    Burst Strength

    (psi)

    32 ECT Single Wall (SW) 200#40 ECT Single Wall (SW) 250#

    44 ECT Single Wall (SW) 275#

    55 ECT Single Wall (SW) 350#

    42 ECT Double Wall (DW) 200#

    48 ECT Double Wall (DW) 275#51 ECT Double Wall (DW) 350#

    61 ECT Double Wall (DW) 400# Elevated Strength Double Wall

    Remarks

    Do Not Use / Not AllowedMin. Double Wall Requirement

    Elevated Strength Double Wall

    Min. Single Wall Requirement

    Elevated Strength Single Wall

    Do Not Use / Not AllowedDo Not Use / Not Allowed

    2.0 ALLOWABLE CARTON DIMENSIONS

    2.1 ALLOWABLE DIMENSIONS & MINIMUM BOARD STRENGTHS

    The table represents the allowable carton footprint, heights, andminimum carton materialstrengths that are allowed for the various component families:

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    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    Single Wall cartons shall be constructed of C-Flute linerboard. Double Wall cartons shall beconstructed of B-C Flute linerboard.

    There are no exceptions to these minimum requirements. Cardboard strengths less thanthe stated rating and flute are not sufficiently strong enough to withstand overseas

    shipments and possible multiple handlings by the freight carriers.

    Yazaki Packaging Engineering will contact the Component Supplier directly andwork with them when packaging damage is chronic.

    Certain product families and cartons sizes may require stronger board strengthswhen the required minimum board strength is found to be insufficient.

    Carton heights other than 5, 10, 15 or 20 are NOT allowed.

    o Yazakis reasoning for requiring standardized heights of all incoming packaging isbecause mixed pallet loads for outbound shipments must be built from numerous

    component suppliers products/packaging. A Component Suppliers own palletload of parts is frequently dismantled, and new pallet loads are reassembled withvarious other cartons from other Component Suppliers to meet order requirements for

    Yazakis manufacturing locations. Standardized carton heights make it easier to

    assemble mixed pallet loads and keep carton layering level on the mixed pallet loads.

    The Ergonomic Weight Limit for Hand-Held cartons is 30 Lbs (weight of empty carton,interior dunnage, & product combined).

    DOUBLE WALL CARTON

    BOARD FLUTE REQUIREMENT

    (B-C FLUTE)

    SINGLE WALL CARTON

    BOARD FLUTE REQUIREMENT

    (C-FLUTE)

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    YAZAKINORTHAMERICA Rev. 2.1WI No.:YAOM-PE-S12-015W Doc. YAOM-PE-S12-015W

    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    2.2 BULK (LARGE/LONG) CARTONS

    Certain Standardized Parts, such as long plastic shields, may require using longer cartonfootprints in order to fit the part correctly. Yazaki allows the use of 48 x 22 and

    48 x 15 carton footprints with the specified heights shown in the table in Section 2.1.

    If the part is longer than 48, carton footprints should be sized so that the 45 side of thepallet is maintained so that an X x 45 pallet can be loaded 2 across in a sea container

    (i.e., carton widths of 11 , 15, 22 with carton lengths as long as required for thepart to fit).

    Allowable Bulk Carton heights are 10, 15, and 20 (+/- 0.25).

    2.3 CARTON LOADING DIAGRAMS

    The diagram below details the layering method on the pallet for the required cartonfootprints on the 48 x 45 pallet:

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    12 x 11.25

    6 x11.25

    6 x11.25

    6 x11.25

    6 x11.25

    6 x11.25

    6 x11.25

    6 x11.25

    6 x11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    6 x

    11.25

    12 x 22.5 12 x 22.5 12 x 22.5 12 x 22.5

    12 x 22.5 12 x 22.5 12 x 22.5 12 x 22.5

    24 x 22.5 24 x 22.5

    24 x 22.5 24 x 22.5

    24 x 11.25 24 x 11.25

    24 x 11.25 24 x 11.25

    24 x 11.25 24 x 11.25

    24 x 11.25 24 x 11.25

    48 x 22.50

    48 x 22.50

    48 x 15

    48 x 15

    48 x 15

    45"

    48"

    11 1/4" x 6" 12" x 11 1/4" 22 1/2" x 12" 24" x 11 1/4" 24" x 22 1/2"

    48" x 22 1/2" 48" x 15"

    HAND HELD CARTONS

    BULK CARTONS

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    YAZAKINORTHAMERICA Rev. 2.1WI No.:YAOM-PE-S12-015W Doc. YAOM-PE-S12-015W

    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    3.0 GENERAL CARTON CONSTRUCTION REQUIREMENTS

    3.1 DESIGN

    All cartons (Hand-Held & Bulk) shall be RSC (Regular Slotted Containers) with flaps forclosure.

    HSC Style Cartons (removable lid) are not allowed.

    Hand holes should NOT be used, unless specified by YNA Packaging Engineering. Ifhand holes are required, YNA Packaging will notify the component supplier of the handhole requirement.

    Corrugated cartons shall be designed to withstand 90% humidity at 30F - 150Fexposure during handling, extended (40+ days) transit and storage.

    Corrugated box material shall be 100% recyclable. Rice paper or yellow corrugated is notallowed.

    All corrugated cartons MUST have a manufacturer's certificate with ECT (Edge CrushTest) or Burst Strength visible on the bottom of the assembled carton as shown:

    STATE IN

    TIFICA

    THIS DOUBLEWALLBOX MEETS ALL CONSTRUCTIONREQUIREMENTS OF APPLICABLE

    FREIGHT CLASSIFICATIONBURSTING LBS PER

    TEST SQ INCH

    MIN COMB LBS PER

    WT FACINGS M SQ FT

    SIZE LIMIT INCHES

    GROSSWT LT LBS

    CITYAND

    FB

    O

    N

    E

    AM

    BOX

    MAKER

    OX CER

    HERE

    EING

    NTE

    GUARATE

    BOX

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    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    The manufacturers jointfor carton seam closure is preferred to be glued. Staples areacceptable as long as no part of any staple is protruding out from the carton material(staples create possible snag points for parts and injury concerns).

    o If stapling the manufacturers joint, metal staples should be no less than0.103 wide and 0.023" thick.

    Cartons should be closed with tape at every location flaps meet with each other and withthe main carton body. At least 6 tape locations shall be used per RSC carton.

    Manufacturer's Joint (Glue

    Preferred, Staples allowed)

    1

    2

    3

    5

    4

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    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    OK for use inside of carton OK for external

    pallet load

    brac ing / stability

    1

    2 3

    4

    RSC CARTON

    3/4" Masking Tape

    Minimum of 3 Tapes

    per Corner Post

    3.2 CARTON CORNER POSTS

    To ensure stacking strength, carton corner posts may be used inside of cartons (hand-heldand bulk) when increased packaging strength is deemed necessary.

    Compressed Circular (paper tubes) and Triangular Posts (Double Wall Cardboard) may beused inside of any carton to provide additional stacking strength.

    If used internally, corner posts should be installed using wide masking tape as shownin diagram below. Use a minimum of three spot tapes to secure each corner post.

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    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    Laminated L-Shaped posts are not preferred inside of cartons because they do not provideadequate support due to lack of surface area, but may be used externally on pallet loads toprovide stability if necessary.

    L-Shaped Corner Posts

    should set on top of wooden

    pallet and be as tall as the

    entire pallet load. Corner

    Posts should be contained

    inside of Stretch Wrap.

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    YAZAKINORTHAMERICA Rev. 2.1WI No.:YAOM-PE-S12-015W Doc. YAOM-PE-S12-015W

    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    4.0 CARTON UTILIZATION REQUIREMENT

    Yazaki North America is heavily focused on the maximum utilization of all shippingcontainers, starting with the primary pack (carton) through the final conveyance (trucking

    trailer & sea container). Cartons that are under filled are both costly to transport, and also

    increase the chance of damage to the overall packaging system and the parts contained.Therefore, Yazaki is imposing aMinimum Carton Utilization Requirementfor all

    components. Suppliers will be notified if they ship parts which do not meet this

    minimum utilization requirement.

    Supplier should select the carton footprint and height which best fits the Vertical CartonUtilization and Product to Carton Footprint Utilization Requirements:

    Vertical Carton Utilization is defined as: Product Fill Height / Carton Height

    o Minimum Vertical Carton Utilization shall be at least 90%.

    Product to Carton Footprint Utilization is defined as:L x W of Product Fill / L x W dimensions of Carton

    o Product to Carton Footprint Utilization shall be a minimum of 80% in a fullypacked carton.

    Vertical Carton

    Utilization

    Requirement:

    90%the Height

    of Carton

    90%

    10%

    Product to Carton Footprint

    Utilization Requirement:

    80%of L x W of Carton 80%

    (L)ength

    (W)idth

    (H)eight

    EXAMPLE: CARTON SHOWN PACKED WITH LOOSE PRODUCT

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    YAZAKINORTHAMERICA Rev. 2.1WI No.:YAOM-PE-S12-015W Doc. YAOM-PE-S12-015W

    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    5.0 PALLET CONSTRUCTION

    5.1 PALLET DIMENSIONS

    Yazaki strives for maximum utilization of sea container and trucking trailers. The bestoverall pallet footprint for full utilization of these conveyances is 48 x 45.

    All component suppliers of Standardized Parts are required to ship product on

    48 x 45 pallets.

    o Exceptions will be reviewed and may be given to a supplier whos shippingvolumes do not fulfill full layers or full pallet loads on the 48 x 45 pallet, orwhos product type requires specialized packaging/dimensions.

    o NOTE: Suppliers whos shipment volumes which do not warrant the use of the48 x 45 pallet (example: supplier normally ships parts via UPS) are stillrequired to ship their product in carton sizes which would cube/fit the 48 x 45

    pallet and meet the carton height requirements previously stated in this document.

    5.2 MATERIALS & CONSTRUCTION

    Required pallet footprint with tolerances shall be 48 x 45

    Stringers Deck Boards48 (+0 / -1/4) x 45 (+0 / -1/4)

    Pallets must provide a 4-way fork entry and be of double face non-reversible woodconstruction.

    Pallets other than wood construction are to be reviewed and approved by Yazaki-Packaging Eng. Dept.

    When shipping on wooden pallets, shipping documentation must include a notation thatstates: "THIS SHIPMENT CONTAINS WOOD PACKAGING MATERIAL

    WHICH MEETS THE ISPM 15 STANDARDS AND IS MARKED

    ACCORDINGLY."

    Do not use pallets with rotted or decayed lumber, knots/knotholes, bark, or splinteredwood. Check for splits that will affect holding strength or interfere with nailing.

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    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    All nails should be flush to surface of wood or recessed slightly. Recycled pallets whichare not sound or that are not within the tolerances (+ 0 / - 0.25) of the required palletfootprint of 48 x 45 are not allowed. Do not use wooden pallets which show signs of

    insect infestation. Pallet quality is the foundation for ensuring overall packaging system

    quality and minimizing packaging system failures.

    o All wooden pallets used to ship product to Yazaki North America must meetISPM 15 - Guidelines for Regulating Wood Packaging Material in

    International Tradeand be stamped with the certified marking as shown.

    o The required Yazaki pallet footprint is shown below.

    The combined surface area of deckboards must be equal to or greater than 50% of theactual surface area of the pallet footprint. In example above, deckboard widths are 4,4, 8, 4, & 4 = 24. Length of pallet is 48. 24 x 45 / 48 x 45 = 50% surface

    coverage and is technically acceptable. Larger surface coverage is preferred. This

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    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    Entire top edge of

    cartons covered

    with stretch wrap

    Stretch wrap

    includes all 4

    corners of pallet

    Stretch Wrap

    overlaps minimum

    of 40% per wrap

    requirement provides adequate support for the bottom layer of cartons so that they do notdrop between the deckboards and cause failure/crushing of the entire pallet load or allow

    spearing of the undersides of cartons by hi-lo forks.

    6.0 PALLETIZATION

    6.1 GENERAL REQUIREMENTS

    Maximum pallet load height of cartons + the pallet should be no higher than 50.

    As previously stated, allowable hand-held carton heights are 5, 10, and 15.Allowable Bulk carton heights are 10, 15, and 20. These heights are required to

    make an overall pallet load height of 50.

    Yazaki allows its Component Suppliers to select the best carton footprint (L x W) of theirproduct. Carton footprints selected shall cube/fit to within 1 of the length and 1 of the

    width of the 48 x 45 pallet.

    Carton footprints should completely cube out a full layer on the pallet with no overhang.

    6.2 STRETCH WRAP

    The use of stretch wrap to secure the cartons to the pallet is preferred. The stretch wrapshould start at the floor and include all 4 corners of the pallet multiple times (3+

    times each corner) in order to fully secure the pallet and minimize shifting of the cartons

    in transit.

    Required application is a minimum of one layer of stretch film covering 100% of ULwith all seams overlapped a minimum 40%. Edges of top layer of cartons must be

    covered on all 4 sides as shown below.

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    YAZAKINORTHAMERICA Rev. 2.1WI No.:YAOM-PE-S12-015W Doc. YAOM-PE-S12-015W

    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    6.3 BANDING

    If banding is used, the banding (minimum 0.5 wide x 0.021 thick) must be extrudedNylon Polypropylene, or made of pre-elongated (oriented) material and able to contract

    upon itself the extent of its stretch created upon application. Steel banding is NOTALLOWED for Standard Item Components.

    A minimum of 4 banding straps should be used (2 for length, 2 for width direction of

    pallet). Additional banding straps (5 or more) should be used if the cartons beingpalletized are not in a 2 x 2 layer arrangement on the pallet in order to secure each

    column of cartons on the pallet.

    Fusing straps or crimp seals should be used to secure banding. Use of buckles is notacceptable unless approved by Yazaki Packaging Engineering Dept.

    6.4 PALLETIZATION OF CARTONS ON PALLET

    A Pallet Load packaging system shall withstand a stacking height of 100 (2 Pallet Loads

    high) in transit and arrive in a satisfactory condition at the final point of use (Mexico orAsia). All container systems shall have sufficient structural integrity to support normal

    handling and storage. Carton integrity must be maintained so pallet loads can be safelystacked in static (non-transit) storage three pallet loads high or to a height of 12 6,

    whichever is greater.

    Cartons must NOT overhang the pallet base at any location. Overhanging cartonsdestroy the vertical stacking strength of the entire pallet load and facilitate crushing of the

    cartons. Overhanging Cartons can lose up to 50% of their vertical stacking strength.

    NoOverhang

    allowed!

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    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    NOT OK

    NOT

    OKOK

    OK

    Cardboard

    Layer Pad

    At least 2 opposite edges of carton MUST be completely supported by the top deckboardsof pallet so that all 4 corners of the carton rest upon the deckboards. Any carton that isfloating or suspended with less than two edges of the carton fully supported by the

    deckboards creates the risk of dropping through the deckboards and causing the unit load

    to fail. Cartons gain the majority of their stacking strength from their corners.

    If carton sizes selected are not sufficiently supported on two opposite edges by thedeckboards of the pallet, a single layer of 48 x 45 cardboard that is no larger than the

    pallet shall be used between the pallet and the bottom layer of cartons to ensure an evenlayer and that the cartons do not drop between the deckboards.

    Always make sure to stack pallet loads so that the support (vertical walls and corners) ofthe cartons support each other in straight alignment.

    Palletizing Cartons in staggered/brick layering fashion is not allowed.

    NOT OK: "Bricklayering" or Interlocking patterns are

    not allowed

    OK: Cartons are aligned vertically

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    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    7.0 SUPPLIER TEST SHIPMENTS

    7.1 A TEST SHIPMENT MAY BE REQUIRED FOR THE FOLLOWING REASONS:

    New Component Supplier.

    Change of Part, Packaging, or Shipping Method.

    New Part.

    As deemed necessary.

    o Each test shipment shall be coordinated with Yazaki Packaging Engineering.

    o Each test shipment shall be labeled on all 4 sides of the pallet load with large,brightly colored yellow labels. Specific trial information required on labels will

    be provided by Yazaki Packaging Engineering.

    8.0 SHIPMENT DAMAGE

    8.1 DAMAGE DOCUMENTATION & RESOLUTION

    Yazaki Components Warehouse documents all incoming packaging and product damagefrom all Component Suppliers.

    Yazaki Warehouse & Packaging Engineering will investigate & determine the cause ofdamage (carrier vs. supplier packaging) and alert the Component Supplier if it is decidedthat the Component Suppliers packaging is not sufficient and needs to be improved.

    The Component Supplier & Yazaki Packaging Engineering shall work together on apackaging improvement plan in order to achieve resolution. Packaging Trials may berequired to ensure positive effects before full implementation of an improved packaging

    system.

    If a packaging improvement plan is not worked towards, followed or achieved in a timelymanner by the Component Supplier:

    o GQRS reports and/or charge backs for damaged packaging & product may beissued to the Component Supplier.

    o Component Supplier Rating may be affected.

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    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    9.0 LABELING

    9.1 CARTON LABELING

    Each carton shall be labeled with 2 labels on adjacent corners as shown below:

    Refer to YAOM-PE-S12-014WYNA Component Supplier Carton Barcode Label

    Guideline for specific carton barcode labeling format and design requirements.

    9.2 MIXED PALLET LOADS: ALLOWABLE SITUATIONS & LABELING

    Mixed Loads (pallets with multiple part numbers):

    o Are allowed if the Yazaki order of one part number is not enough to complete afull pallet load of that part number.

    o Are allowed if the Cartons used to ship product to Yazaki are very small in natureand do not take up a complete layer on the pallet.

    o The same part number from the same order # should be kept on the same pallet tocreate a full pallet load of that part number. Leftover cartons from this partnumber which do not complete the next full pallet load may be used to make a

    Mixed Pallet Load with additional leftover cartons/part numbers.

    OK: 2 Labels per

    Carton on adjacent

    sides of carton

    NO GOOD: Labels are

    on opposite sides of

    cartonOK!

    OK!

    NO GOOD!

    NO GOOD!

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    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    A

    A

    A

    A

    A

    A

    A

    A

    B C

    B C

    B

    A

    A

    Back Column, 3 boxes, hidden

    A

    A

    B

    B

    C C

    C A

    C B

    A C

    C

    B

    C

    Back Column, 3 boxes, hidden

    OK! Same part levels are stacked together.NO GOOD! Part numbers are not stacked together.

    Same part levels are all over in pallet.

    The following methodology shall be followed by the component supplier whenpalletizing orders for a Yazaki Distribution Center:

    o Final Mixed Load Pallets with multiple part numbers shall be packed so that thesame part numbers are grouped together on the pallet as shown below:

    MIXED PALLET LOAD

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    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    9.3 MASTER & MIXED LOAD GENERAL INFO

    MASTER PALLET LOAD LABELo A Master Pallet Load label shall be used to identify the total quantity of parts on

    the pallet when the part number shipped on the pallet is the same.o The serial number area of theMaster Load Label shall contain the following

    information for each carton on the pallet: Part Number

    Quantity (total pieces on pallet) Serial Number of each carton on the pallet

    MIXED PALLET LOAD LABELo A Mixed Pallet Load label shall be used to identify the quantities and part

    numbers shipped when there are multiple part numbers on the pallet.

    o The serial number area of theMixed Pallet Loadlabel shall contain the followinginformation for each carton on the pallet:

    Part Number Quantity of that part number Serial Number of the carton

    MASTER & MIXED PALLET LOAD LABEL LOCATIONSo There shall be a minimum of 1 Master or Mixed labels for each pallet shipped.o The label location shall be on the bottom layer of cartons on the pallet, with the

    Master or Mixed label facing the loading direction into the trailer for easyvisibility.

    o Master & Mixed labels shall be placed in such a manner that when the pallet loadis broken down, the Master/Mixed label remains on the pallet load until the very

    last layer of cartons is accessed. If the pallet is banded:

    The banding shall not cover the Master/Mixed label.

    The Master/Mixed label shall not be placed over the banding. If the pallet is stretch-wrapped, the Master/Mixed label shall be placed

    underneath the stretch-wrap on the bottom layer of cartons.

    o Master Load Labels and Mixed Load Labels shall be placed so that they do notcover any of the cartons barcode (handling unit) labels.

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    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    o The diagrams below illustrate the placement of the Master and Mixed LoadLabels on the final pallet load.

    A

    A

    B

    A

    A

    B

    M

    MMaster OR Mixed Labels in BOTTOM position on pallet in position that will NOT

    destroy the label after banding or stretchwrap is removed. (Label is NOT placed over

    banding OR label is inside of stretchwrap)

    M

    BANDED PALLET STRETCHWRAPPED PALLET

    Master/Mixed Label placed on bottom layer of cartons so that it is

    clearly visible, not covering carton (handling unit) labels, and not

    over the banding.

    Master/Mixed Label placed on bottom layer of cartons underneath

    stretchwrap so that it is clearly visible and not covering carton

    (handling unit) labels

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    Component Supplier Packaging Guidelines forStandard Parts

    Date 11/12/10

    This document is uncontrolled if printed on paper, unless it is otherwise clearly identified as controlled. Prior to

    use of an uncontrolled print-out, the QMS on-line documentation system must be referenced to ensure that the mostcurrent revision is utilized.

    10.0 ENVIRONMENTAL POLICY & SUBSTANCES OF CONCERN (SOCS)

    Yazaki North America is committed to being a responsible corporate citizen by servingas an example in environmental protection and preservation. Packaging that the supplier

    selects affects the environment in multiple ways from production of the material to end/finaluse, and must be manufactured to permit reuse or recovery when packaging waste is disposed

    of. Recovery includes the recycling of packaging materials, separate composting of

    biodegradable packaging, and energy recovery through incineration. Suppliers should select

    packaging that:1) Is created/manufactured from a renewable resource2) Has limited effect on the environment during production and after end-use 3) Has the capability of being reused or recycled

    Fulfilling these packaging requirements will ensure that our operations and activities donot adversely affect the communities in which we operate and the environment in general.

    PROHIBITED PACKAGING MATERIALS & SUBSTANCES OF CONCERNo Suppliers shall NOT use the following items in their packaging due to

    environmental effects & concerns: EPS (Expanded Poly Styrene) - blocks, inserts, packing peanuts, etc. Materials containing lead, cadmium, mercury or hexavalent chromium

    11.0 PACKAGING QUESTIONS & ISSUES

    Packaging issues may be communicated to Yazaki Packaging Engineering by contactingSteve Giebelhaus, Packaging Engineer:

    [email protected]