packaging manual - QUINThis packaging manual applies to deliveries to the QUIN plants in Wałbrzych...
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QUIN GmbH Gutenbergstr. 16 71277 Rutesheim packaging manual Last revised: January 2013
Transcript of packaging manual - QUINThis packaging manual applies to deliveries to the QUIN plants in Wałbrzych...
QUIN GmbH
Gutenbergstr. 16
71277 Rutesheim
packaging manual
Last revised: January 2013
1
Contents
1. General information ..................................................................................................... 2
1.1 Objective of this manual ..................................................................................... 2
1.2 Scope of this manual .......................................................................................... 2
1.3 Supplier’s obligations ......................................................................................... 2
1.4 Packaging requirements ..................................................................................... 3
1.5 Contact ................................................................................................................. 3
2. Packaging planning and specification ........................................................................ 4
2.1 Release process .................................................................................................. 4
2.2 Flow chart for packaging planning..................................................................... 5
2.3 Packaging materials ............................................................................................ 6
2.4 Quantity of containers ........................................................................................ 7
3. Packaging types ........................................................................................................... 9
3.1 Returnable packaging ......................................................................................... 9
3.1.1 Universal load carriers ........................................................................................ 9
3.1.2 Special load carriers ........................................................................................... 9
3.2 Disposable packaging ........................................................................................10
3.3 Bundles ...............................................................................................................10
4. Special requirements for sea and air freight .............................................................10
4.1 Sea freight ...........................................................................................................10
4.2 Air freight ............................................................................................................10
5. Forming and securing loading units ..........................................................................11
5.1 Forming loading units ........................................................................................11
5.2 Stackability .........................................................................................................11
6. Shipping documents and container labelling ............................................................12
6.1 Container labelling .............................................................................................12
6.2 Single VDA label (210 mm x 148 mm) ...............................................................12
6.2.1 Single VDA label 4902 for small load carriers (210 mm x 74 mm) ...................13
6.2.2 Contents of the VDA material tag ......................................................................13
6.2.3 Small load carrier labelling ................................................................................14
6.3 Delivery note .......................................................................................................14
6.4 CMR bill of lading or shipping order .................................................................15
7. Annexes .......................................................................................................................16
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1. General information
The following guidelines and regulations for the supply of goods to QUIN GmbH and its plants are to
be understood as a contractual agreement supplementing the general terms of purchase.
1.1 Objective of this manual
This manual is to aid the development of optimal packaging that safeguards the smooth flow of
materials between the supplier and QUIN GmbH with consideration to all quality, ecological, and
economic aspects.
1.2 Scope of this manual
This packaging manual applies to deliveries to the QUIN plants in Wałbrzych (Poland), Brașov
(Romania), Wuqing (China), and Rutesheim (Germany). This packaging manual regulates the
operations involved in the packaging of production parts, semifinished products, and commodities.
1.3 Supplier’s obligations
When not agreed otherwise, the supplier is obliged to deliver products in the standard
packaging from the start of series production.
An adequate quantity of packaging materials must be available at all times for shipping.
The supplied containers must be filled to the maximum level. Changes to the filled level must
be agreed with Quin GmbH.
The prescribed labelling must be observed.
Before they are reused, the load carriers must first be cleaned of contaminants like e.g. dust,
soiling, moisture, etc., that may have an adverse effect on the quality of the components.
Cleaning also extends to the removal of labels and label residue. Returnable packaging that
cannot be cleaned may not be reused.
Loading and unloading must not contaminate the load carriers or components.
Quin containers may not be scrapped without the prior consent of Quin Logistics.
The supplier is liable for additional expenses incurred through failure to observe these specifications.
These incurred costs will be charged to the supplier in the form of repackaging and additional
container fees. Moreover, Quin is entitled at any time to refuse acceptance of the delivery and to
cancel the order. The costs of losses are offset against the replacement value. When the originator
cannot be established, the costs are charged equally to each party.
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1.4 Packaging requirements
The specifications in this packaging manual and the national and international regulations must be
observed. Disposable packaging is used after agreement and primarily for overseas shipping,
replacement parts supplies, and pilot runs. Quin GmbH reserves the right to refuse acceptance of
consignments that are not delivered in the agreed packaging.
Irrespectively of the packaging type chosen, the packaging must fulfil the following requirements:
The packaging must be such that the components arrive undamaged at the recipient. Visible
surfaces may not come into contact with the packaging at any time over the transport route.
When corrosion protection is required, it is the supplier’s responsibility to provide for adequate
packaging.
Consignments must be placed exclusively in clean packaging. This should allow ease of
cleaning and not pose a danger to persons.
The containers should be filled for the optimal balance, and their bundles must allow stacking.
There must be adequate stability.
Loading and unloading must be simple and also allow the use of ground conveyors.
The supplier is responsible for adequate transport locks.
The packaging must allow ease of handling and ergonomic withdrawal of contents.
Standardised labelling must be observed for the correct identification of the components.
Only one reference number may be packaged in each loading unit. Deviations must be agreed
with Quin GmbH Logistics Planning.
1.5 Contact
The contact in the planning phase is Logistics Planning. The standard packaging is supervised by the
affected user departments at the production plants. All contacts are listed in Annex 1.
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2. Packaging planning and specification
The packaging is specified at all times by the supplier that bases its choice on the requirements in the
QUIN packaging manual.
2.1 Release process
The packaging is set down in writing on the packaging data sheet (see Annex 3). All new or changed
packaging specifications are sent to the supplier who must complete and return the sheet to Quin
GmbH within fifteen working days. Until further notice, the packaging is valid for all change indexes. It
becomes legally binding when undersigned by the supplier and the responsible logistics planner at
Quin GmbH. The release of packaging does not exempt the supplier from its responsibility to deliver
parts free of damage. QUIN reserves the right to determine its packaging service provider.
Deviations in justified cases (e.g. pilot run packaging for reruns) must be agreed with Quin GmbH
before delivery.
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2.2 Flow chart for packaging planning
QUIN Supplier
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2.3 Packaging materials
The supplier must develop environmentally friendly packaging complying with the regulations in the
affected country. This must be designed for the volume of the components and consist of
environmentally compatible, recyclable materials. Quin GmbH introduces disposable packaging to
suitable recycling processes. The disposal of returnable packaging is specified from project to project.
Overview of QUIN approved materials:
Table 1 – Packaging materials
Material
Approved materials
Forbidden materials
Composites
Composites are not permitted
General plastics
Disposable
Returnable
PE, PP, PS, PET marking under DIN 6120 PE, PP, PET, ABS marking under DIN 6120
PVC, expanded polystyrene PVC, expanded polystyrene
Plastic packaging material
Precut plastic sheeting
Bags and sacks
Protective and insulating caps
Deep drawn inlays
Foams
PE PE PE PE, PP, PS, PET, ABS PE (returnable also PP)
Cardboards and paper
Marking and administration must comply with RESY
With water insoluble coatings (e.g. wax, bitumen, oil paper, self adhesive paper tapes)
Strapping
PP, PET
Steel strips, polyamide strips, polyester strips
Anticorrosion paper
Only VCIs whose recyclability with paper/card has been verified
Wood
In accordance with IPPC, ISPM15
Pressboards / pressboard pallets Impregnated, painted, coated wood
Stuffing
Corrugated cardboard, paper
Chips of vegetable products Chips or shaped parts of expanded polystyrene
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2.4 Quantity of containers
When using returnable packaging, the supplier must determine the required quantity of containers and
agree this with QUIN. The number of containers determined is based on circulation days (CDs). The
supplier is obliged to specify the circulation days in accordance with the table below.
Supplier Carrier QUIN
Production
1 CD
Transport
2)
Warehouse for full products
3 CD
Delivery cycle
X CD1)
Delivery cycle
X CD1)
Safety stock
X CD3)
Production
1 CD
Warehouse for empties
1 CD
1) For delivery cycle
1 x week: 2.5 CD
2 x week: 1.5 CD
3 x week: 1 CD
2) In Germany: 1 CD
Between Germany and Poland 1,5 CD
Between Germany and Romania 3 CD
In case of empties return please multiply by 2.
3) For EU: 1 CD
For Europe (non-EU): 3 CD
Rest of the world: 5 CD
Table 2 – Calculating circulation days
Adding each of these process steps returns the circulation days.
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3. Packaging types
The target is the consistent organisation of the logistics chain with standardised packaging and the
utilisation of the associated potential in partnerships. Depending on the quality and handling
requirements, either universal or special load carriers are used.
3.1 Returnable packaging
3.1.1 Universal load carriers
The small and large load carriers used differ from project to project and must be agreed with Logistics
Planning. The components must be protected against damage, moisture, dust, and soiling as
described in the packaging requirements. This can take the form of spacers, interim layers, or sheeting
and an adequate plastic cover. Small load carriers must comply with the VDA standard. The top layer
of small load carriers must be provided with a plastic cover, and the layers filled whenever possible
over their whole surface.
The following small load carriers can be used:
KLT 4314 (400 x 300 x 147.5 mm)
KLT 6414 (600 x 400 x 147.5 mm)
KLT 6428 (600 x 400 x 280 mm)
3.1.2 Special load carriers
A special load carrier is used when universal load carriers are not possible. Following agreement with
the Quin GmbH user department, the supplier plans, designs, and procures the special load carriers.
Special load carriers are also large and small load carriers with inlays adapted specially to the
component. These can consist of various materials that are listed in Section 2.4.
Figure 2 – EPP foam Figure 2 – Deep drawn insert in a small load carrier
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3.2 Disposable packaging
Disposable packaging is developed and procured by the supplier. Disposable packaging is used
following agreement and only when load carrier returns entail high costs, e.g. for overseas shipping,
replacement parts supplies, or pilot runs. Planning must take into account the following:
The packaging must be such that the components arrive undamaged at the recipient. Visible
surfaces may not come into contact with the packaging at any time over the transport route. If
necessary, they must be provided with an adequate protective sheet. When corrosion
protection is required, it is the supplier’s responsibility to provide for adequate packaging.
Disposable packaging is generally provided by the supplier and is charged to the supplier’s
account.
The standard measurements of the loading unit and its modular layout must be adapted to the
recommendations under VDA 4500 and 4525. Deviations must be agreed with QUIN Central
Logistics.
The sealing aids used must be suitable for the size and weight of the packaging unit.
Loading units should allow two-high stacking.
3.3 Bundles
Bundles are made up of several single constituents, e.g. pallet, small load carrier, top cover.
4. Special requirements for sea and air freight
4.1 Sea freight
The packaging must be such that the effects of cold, moisture, or heat and the extreme loads caused
by goods movements cannot prove detrimental to the product quality. In addition, the packaging
should exhibit a space saving, convenient design that is suitable for loading with ground conveyors. At
the same time, the measurements and weights must be adapted under economic aspects to all
transport means in the logistics chain. The provisions applying in the countries of destination must be
observed.
4.2 Air freight
Air freight consignments should be placed in space saving, lightweight, and robust packaging that
must also protect the goods from extreme climatic and mechanical effects both to and from the airport.
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5. Forming and securing loading units
A loading unit is a shipment whose constituents of objects and packaging aids are such that they can
be handled, transported, stacked, and placed in storage as a single unit.
5.1 Forming loading units
The basic size of loading units may not be exceeded by the packaged goods or the units themselves.
They must allow at all times their handling by ground conveyors and automated conveying
installations. The measures for securing the loading units must not restrict the access height for
forklifts. The loading units must be secured to prevent the packaging from slipping during transport.
Possible measures are:
pallet cover top
plastic strapping
Strapping must not cut into cardboard packaging. Angle beads must then be used here. Withdrawing
parts of a loading unit’s contents must not affect the stability of the remaining contents.
5.2 Stackability
When the quantity released cannot fill completely a layer, this layer must be filled with empty
containers. Empty containers must then be labelled as empty.
Wrong Wrong Right
Wrong Right
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Q1
6. Shipping documents and container labelling
6.1 Container labelling
Container labels serve as a unique ID for the goods and unit load devices both for the inhouse
material flow and on the transport route between supplier, carrier, and consignee. The supplier must
therefore ensure that all unit load devices are provided with an up to date, carefully completed, and
barcoded material tag complying with VDA recommendation 4902 (current version). In particular the
details on the material tag must agree with the contents of the unit load device. For the purpose of
unique IDs, the supplier is obliged to remove completely all outdated material tags and labelling on the
unit load devices before they are filled.
In the event of absent, illegible, or incompletely filled material tags, QUIN reserves the right to bill any
additional expenditure incurred by this failure to comply with the labelling provisions. The supplier can
likewise be billed for any additional expenditure incurred as a result of incompletely removed material
tags, incorrect securing, or other violations to the regulations contained in these logistics guidelines.
VDA recommendation 4902 describes the following two formats.
6.2 Single VDA label (210 mm x 148 mm)
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6.2.1 Single VDA label 4902 for small load carriers (210 mm x 74 mm)
6.2.2 Contents of the VDA material tag
Field number Field name Example
1 Consignee QUIN GmbH
Rutesheim
2 Unloading point – storage location – distribution key S
3 Delivery note no. 82676745
4 Supplier address Some Company Ltd,
99999 Some City
5 Package weight excl load carrier (kg) 2.848
6 Package weight incl load carrier (kg) 8.248
7 Number of packages for this delivery 1
8 QUIN reference number 3001899
9 Actual filled quantity 252
10 Name, delivery, service (name of the goods) LST W221
11 Container reference number 03348.7101-03
12 Supplier number (customer reference number) 50326
13 Date 22/10/2012
14 Design change status 002
15 Package number 20198692
16 Batch number (that the manufacturer assigns to a batch
or production lot)
520153/1-1
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6.2.3 Small load carrier labelling
The container label in the VDA card pocket must be attached to an easily visible site on the face or
long side and may not project over the outside edge of the packaging.
The material tag chosen must be resistant to environmental effects and the transport environment so
that it can be machine read at the delivery point. In addition, the container label can be secured with
max four adhesive film strips or points that can be detached without residue.
6.3 Delivery note
The collection of materials at QUIN goods receipt requires a delivery note that provides a unique
description of the delivery. The delivery notes for each shipment must be:
a) affixed securely and in duplicate in adequate sleeves to the outside of their packages when the
consignment is shipped via a parcel service.
b) handed over together with the freight documents to the driver when the consignment is shipped by
carrier.
The delivery notes must contain at least the following:
delivery note number
name and address of the sender
name and address of the recipient
date of the delivery note
name or possibly signature of the packager
gross weight, net weight
delivery note items
name of the orderer (contact person)
purchase order number
purchase order date
purchase order item
QUIN article reference
QUIN article description
supplier’s article number
delivery quantity (per purchase order item) in quantity units
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6.4 CMR bill of lading or shipping order
The shipping order serves Container Control as a basis for regular account reconciliation and as a
control instrument for the examination of container quantity and quality at goods receipt. The shipping
order used must comply with VDA 4922.
This requires complete, correct, and unique details that must be entered on the shipping order as
follows:
consignor
loading site
supplier no.
shipment, loading, reference no.
packaging type
number of containers
The driver or carrier confirms with its signature the proper condition and completeness of the
shipment. The supplier must provide shipping documents that have been completed properly. The
supplier must bear the costs for acquiring details that are not included on the shipping documents.
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7. Annexes
Annex 1: Contacts at central QUIN logistics Rutesheim
Annex 2: Contacts at plants
Annex 3: Packaging data sheet
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Annex 1: Contacts at central QUIN logistics Rutesheim
Name/position Phone Email
QUIN Rutesheim
Ms Drulea – Logistics Planning
07152 33002-501
Mr Müller – Logistics Management
07152 33002-605
Mr Fey – Operative Logistics
07152 33002-613
Annex 2: Contacts at plants
Name/position Phone Email
QUIN Romania
Ms Reimesch – Logistics Management
0040 368 443-304
Mr Godri – MRP
0040 368 443-314
Name/position Phone Email
QUIN Poland
Ms Pisla – Logistics Management
0048 74 84072-36
Ms Novosielska – MRP
0048 74 84072-31
Ms Orlon – MRP
0048 74 84072-30
Name/position Phone Email
QUIN China
Mr Thurner – Executive Management
0086-13810710154
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Firma Firma
Adresse Adresse
PLZ, Ort PLZ, Ort
Land Land
Kontaktperson Kontaktperson
Abteilung Abteilung
Telefon Telefon
Telefax Telefax
E-Mail E-Mail
Verkäufer Lieferant Einkäufer
Teile-Bezeichnung:
Sachnummer Arau:
Teile-Gewicht (kg):
Empfängerwerk:
Laufzeit:
Lieferfrequenz:
Jahresmenge:
Verpackungsdaten Volumen (m³): Stück / HU (Palette):
Volumen (m³): Stück / Behälter:
Währung: €
L B H Preis/Stück Preis/HU
Invest ohne Verzinsung Zinssatz (%)
Umlauftage entspricht HU
% entspricht HU
Verpackungskosten pro Stück gesamt
Entwurf Freigabe Teile-Bezeichnung:
Sachnummer Quin:
Teile-Gewicht (kg):
Anzahl/
HU
1 = Einw eg
2 = Mehrw eg
Beschaffung der Verpackung KU / LI
Leihgutkonto für Mehrwegverpackungen KU / LI
KU / LI
Leergutrücktransport KU / LI
Verpackungsdaten Volumen (m³): Stück pro Palette:
Volumen (m³):
Tara Gewicht Netto Gewicht
Quin GmbH
Tara Gewicht
Kunden- / Lieferantendaten
Status Verpackungsdatenblatt:
Erstellungsdatum:
Stapelfaktor Verpackung (befüllt):
Mehrweganteil pro Stück Einweganteil pro Stück
Sach-Nr.
Deckel
1 = Einweg
2 = Mehrweg
Holzstab
Kunstofftiefziehlayer
KLT
Kunststoffband
Tara Gewicht /
HU (kg)Lieferant Verpackung
Gewicht
(kg)
Masse (mm) Anzahl /
HU
Sachnummer Lieferant:
Aussenmasse Verpackung (mm):
Armortisation nach Stück
Werkzeugkosten Verpackung
Status Verpackungsdatenblatt:
Beschriftung nach Arau Vorschrift
Brutto Gewicht
Reinigung der Verpackung
Aussenmasse Verpackung Leergut (mm):
Erstellungsdatum:
Entwurf Freigabe
Verpackungskosten im Teilepreis enthalten
Lagerung der Verpackung in freiem Gelände
Invest mit Verzinsung
Netto Gewicht
Befüllung Verpackung: manuell automatisch
Bezeichnung
Verpackungsbestandteile
Stapelfaktor Verpackung (befüllt):
Verpackungsdatenblatt Kunde Lieferant
Aussenmasse Verpackung Leergut (mm):
Aussenmasse Verpackung befüllt (mm):
Fertigungslosgrösse:
Anteilige Verpackungskosten / Komponente
Bedarf Mehrwegverpackung
Brutto Gewicht
Bezeichnung
Verpackungsbestandteile
Schwund, Defekte
Mehrweganteil pro Palette
Entspricht Amortisation in Jahren
Einweganteil pro Palette
Verpackungsdatenblatt Kunde Lieferant
Zusätzliche Vereinbarungen
Quin
Quin
Quin
Quin
ja
ja
ja
nein
nein
nein
KU = Kunde / LI = Lieferant
Foto 2Befüllung
Foto 3Versandbereit
Foto 1: Inlet Foto 2: KLT Foto 3: Befüllung Foto 4: Versandbereit/
Anlieferungszustand / Leergutrücklieferung (Erforderlich bei Einsatz von Mehrwegverpackungen)
Foto 3Leergutrücknahme
Foto 3Befüllung
Annex 3: Packaging data sheet
