PACKAGING - DOC by 8CRGz2U3

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									REMY INC                      PACKAGING CONTAINERIZATION




   PACKAGING
       &
CONTAINERIZATION




For Reference Only   PC – 1                 REV 11/23/2011
REMY INC                                                 PACKAGING CONTAINERIZATION




PHILOSOPHY
Remy Inc‟s packaging and containerization philosophy is to provide product to properly
support the operator. This package should present the part in the proper orientation, within
the ergonomic guidelines, while ensuring part quality. The appropriate package will:

          Ensure operator safety
          Guarantee part quality
          Maximize production efficiency
          Minimize waste
          Support the product‟s lowest total cost structure

Each product purchased shall be analyzed to support the product‟s lowest total cost structure.
The packaging and containerization guidelines are documented in the following section to
assist in the analysis required.




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REMY INC                                                                         PACKAGING CONTAINERIZATION


                                        TABLE OF CONTENTS
I.     Purpose ...................................................................................................................... 4

II.    Introduction to Packaging.......................................................................................... 4
       A. Compliance .......................................................................................................... 4
       B. Remy Inc Responsibility ..................................................................................... 5
       C. Supplier Responsibility ....................................................................................... 5
       D. General Container Requirements ........................................................................ 6

III.   Packaging & Containerization Initiate / Change Methodology ................................ 9
       A. Packaging Flow Chart ......................................................................................... 11
       B. Methodology........................................................................................................ 12
       C. When to Evaluate Packaging ............................................................................... 13
       D. Guidelines for Decision Making ......................................................................... 14
       E. Ergonomic Guidelines for Standing Workstation ............................................... 15
       F. Ergonomic Guidelines for Manual Material Handling Package Size/Weight ..... 17
       G. Information required to Begin Product Quotation ............................................... 18
       H. Container Decisions............................................................................................. 20
          1. Interior Dunnage ............................................................................................ 20
          2. Returnable Containers ................................................................................... 20
          3. Expendable Containers .................................................................................. 21
          4. Export Considerations ................................................................................... 22
       I. System Sizing Returnable Containers ................................................................. 22
       J. Returnable versus Expendable Cost Analysis ..................................................... 25
       K. Logistics Decisions .............................................................................................. 27
          1. Transportation................................................................................................ 27
          2. Part Combination ........................................................................................... 27
          3. Labels ............................................................................................................ 28
       L. Documenting the Container System .................................................................... 29
       M. Test Packaging..................................................................................................... 34
       N. Conclusion ........................................................................................................... 36

IV.    Standard Container Menu .......................................................................................... 37
V.     Blank Forms .............................................................................................................. 42
VI.    Re-Packaging ............................................................................................................ 49




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REMY INC                                                PACKAGING CONTAINERIZATION


PURPOSE
The Purpose of this section is to outline the packaging requirements for production parts used
or handled within Remy Inc or its affiliate Facilities. The following requirements are made to
achieve optimum part quality and insure “just-in-time” efficiency throughout Remy Inc‟s total
logistics and manufacturing process, including the supply base.

This will be accomplished by:
    Establishing General Containerization guidelines
    Defining the Remy Inc Packaging and Containerization Methodology including:
       -Guidelines for when to evaluate packaging and container options
       -Information to begin product quotation
       -Definitions and Standard Container Menu for returnable and corrugated packages
       -System Sizing for returnable packaging
       -Part/Package Identification
      Providing blank forms

Introduction
The information in this manual when properly applied, will help insure that material arriving
at Remy Inc facilities will properly support the operator, be damage-free and easily
identifiable. It should be noted that Remy Inc approval of the proposed packaging, does not
relieve the supplier of responsibility for non-carrier related pack damage during transit.
Approval only confirms that the pack meets our in-plant material handling and safety
requirements.

Compliance
All suppliers must comply with the Packaging and Containerization Methodology.
Adherence to these requirements is mandatory. Non-compliance will result in a 5 phase
corrective action issued by Remy Inc. Any charges for repackaging and/or disposal will be
billed back to the supplier. Remy Inc also reserves the right to demand supplier presence to
correct any quality problems related to packaging. Any continuous violation or reoccurring
problem will be referred to Remy Inc Purchasing for further actions.




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REMY INC                                               PACKAGING CONTAINERIZATION


Remy Inc Responsibility
Remy Inc is responsible for:
 Establishing packaging and containerization guidelines and standards
 Determining the proper part presentation for the operation
 Communicating point-of-use requirements for the package
 The ergonomic evaluation and approval of all supplier proposed packaging
 Communicating packaging issues / problems to supplier in a timely manner

It is Remy Inc‟s responsibility to communicate the “point-of-use” requirement for part
packaging. Following test package submission and the proper plant approvals, Remy Inc is
responsible for notifying the supplier of the acceptance or failure of the proposed package.

Supplier Responsibility
The supplier is responsible for:
 Compliance with the Remy Inc Packaging and Containerization guidelines
 The design and development of packaging, unless otherwise specified from Remy Inc
 Maintaining accurate Packaging Detail Information at Remy Inc to be kept in the
   Purchasing Department in PPAP files. (Packaging Sketch Form and Part Package and
   Transportation Detail Information Sheets)
 Part quality upon arrival at a Remy Inc facility, Domestic or International
 Any damage to incoming products due to packaging

It is the supplier‟s responsibility to design and develop packaging and interior dunnage to
ensure that all parts and packaging are received damage free. Packaging must assure parts
quality to the final ship-to location (domestic/international). The supplier must provide
packaging that can protect the parts through its methods of transportation and types of
handling from its origin to final destination and intended point of use. Remy Inc may assist
with the packaging design and development but is not responsible or liable for non-
performance of the final pack. The suppliers must ensure that all parts arrive at Remy Inc in
satisfactory quality condition.

Production packaging samples must be submitted to Remy Inc for approval and all suppliers
must have approval before purchasing production packaging. All suppliers are required to
complete and return the Packaging Sketch Form and the Part Package and Transportation
Detail form for all parts shipped to Remy Inc. Both the Packaging Sketch form and the Part
Package and Transportation Detail forms are filed with the Supplier PPAP file. Each must
remain up to date at all times.

Suppliers may not deviate from shipping the quoted and approved packaging. Suppliers may
request a change in packaging or transportation by submitting a Part Package and
Transportation Detail Form and a Packaging Sketch Form.

Suppliers utilizing returnable packaging should maintain a sufficient supply (minimum of
three days supply) of expendable packaging for shipments in the event of container delays or

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REMY INC                                                  PACKAGING CONTAINERIZATION


shortages. Suppliers whose parts are designated to ship in returnable containers must receive
authorization from the appropriate Materials representative PRIOR to shipping temporarily in
expendable packaging. The supplier is responsible to ensure this expendable packaging meets
the following requirements:
   Part quality must remain intact
   Package size must be consistent with the modular container
   The interior dunnage must be consistent with returnable pack

All expendable materials must be legally and economically disposable based on the laws or
regulations of the final destination (domestic/international).

The packaging costs must be included in all part quotations and must be clearly defined in the
piece price. Containerization must be cost justified through an analysis of the cost between
expendable versus returnable containers. The total cost includes inbound and outbound
freight and handling costs associated with using returnable containers. All pricing must be
negotiated through the appropriate purchasing/customer service representatives supporting the
process. All inbound product pricing must go through Remy Inc Purchasing.

General Container Requirements
The following are the basic packaging and identification requirements for production
materials shipped to Remy Inc facilities. These requirements are to be used as guides when
developing or modifying any production package.
   All packs must be efficient, using small lot sizes of 1-hour production per container as
    target. Small, standard sized containers are preferred for lineside use.
   Bulk (large pallet sized) containers are used where part size and weight precludes use in a
    hand tote delivery method. Maximum allowable quantity per container is 1 day Remy
    Inc product usage. In all cases, presenting parts in bulk containers can only be used after
    obtaining approval from Remy Inc Packaging.
   Small parts, i.e. fasteners are exceptions to the 1-hour and the 1-day production system
    requirement. Fastener industry standard containers are acceptable.
       In addition to the standard corrugated containers for the fastener industry. There is an
        AIAG agreed upon returnable for the fastener industry. Please see the Standard
        Container Menu.
   Drums, barrels, cans or pails are NOT acceptable shipping containers for other than liquid
    or granular materials.
   Salvage materials and used containers, pallets, crates, etc., are not to be considered as
    shipping containers without specific approval.
   Any shipping method which would not be consistently the same will not be acceptable
   Containers requiring manual handling are not to exceed 30 lbs. Gross weight
   All shipping containers, pallets, etc. must be of sufficient strength to withstand normal in-
    transit handling and be of a design that will result in delivery of parts in good condition.
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REMY INC                                                         PACKAGING CONTAINERIZATION


      In addition, all shipping methods and containers must comply with all regulations issued
      by the common carriers.
     Containers must consider general ergonomic design guidelines.



Ergonomic Guidelines for Containers

Single Container Hand Held Tote
Optimal Container Design                                  Optimal Handle Design
    Characteristic    Description of Optimal           Characteristic    Description of Optimal
        Area              Characteristics                  Area              Characteristics
Frontal Length         16 in (40 cm)                Diameter           0.75 – 1.5 in (1.9 - 3.8 cm)

Height                 12 in (30 cm)                Length              4.5 in (11.5 cm)

Surface               Smooth, non-slip               Clearance           2 in (5 cm)

Edge                  Non-sharp, without burrs       Shape              Cylindrical

Center of Mass        Symmetric                      Surface            Smooth, Non-slip

Load                  Stable

Gloves Required       No



Optimal Handhold Cut-Out Design
                                Description of Optimal
Characteristic Area
                                   Characteristics
Height                      1.5 in (3.8 cm)

Length                      4.5 in (11.5 cm)

Clearance                   2 in (5 cm)

Container thickness         0.25 in (6.4 cm)

Shape                      Semi-oval

Surface                    Smooth, Non-slip




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REMY INC                                            PACKAGING CONTAINERIZATION


Types of Handles (Best to Worst)
Rank       Handle Name      Picture     Comments


       Contoured gripping
  1
       block (Semi-power)
                                        The contoured gripping block is superior to the
                                        straight gripping block (2) because it provides
                                        more grip security and stability when weight is
                                        handled in high lifts. Both permit a semi-power
       Gripping block                   grip.
  2
       (Semi-power)




  3    Drawer pull (Hook)

                                        Grips 3 and 4 permit a hook grip and work well
                                        for lifts below the chest height; they present
                                        problems for lifts above shoulder height.
       Handhold cutout
  4
       (Hook)




  5    Overhang (Hook)




  6    Rim (Pinch)

                                        Grips 5,6,7, and 8 put pressure on a localized
                                        part of the hand or only permit use of a lateral
                                        pinch grip.

  7    Lodge (Pinch)




  8    Rolled edge




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REMY INC                      PACKAGING CONTAINERIZATION




               Packaging
                    &
             Containerization

              Initiate / Change
                Methodology


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REMY INC                       PACKAGING CONTAINERIZATION




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REMY INC                                              PACKAGING CONTAINERIZATION


                       Packaging Process Flow
             Initiate New Package                       Change to existing
           Advanced Product / Project                       Package
             Management Support

           Manufacturing Engineering
                                                       Central Plant Contact
                                                      Plant Material Manager




                                    Define Package
                                     Requirement




                               Manufacturing Engineering




                              Gather Information to define
                                        System

                           Deliver to Commodity Manager for
                                    Supplier interface

                                          Materials


                               Evaluate Total Cost Model,
                               Chose Supplier, authorize
                                     Test Package


                                  Commodity Manager




                                 Implement and Maintain
                                  New Container System




                                        Plant Materials

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REMY INC                                                PACKAGING CONTAINERIZATION


Methodology
This methodology focuses specifically on how to make packaging and containerization
decisions for an operation. Ideally, a package will properly support the supplier‟s ability to
package directly into the container chosen for the operation. Some major benefits to proper
packaging and containerization for the entire value stream are:

      Reduced inventories to support Just-In-Time delivery
      Improved ergonomics and work cell efficiency
      Minimizing overall costs

Specifically, we must consider:
      Process Inputs
       Part Orientation to operator
         Part orientation to the operator is determined based on the production process and
         the manner in which the operator picks up a part to assemble it to another part or
         place it into an operation for fabrication.
       Rate of use within the operation
         Each process must be operated at a planned process cycle time or production rate,
         which accommodates the customer‟s volume requirement for the day within the
         available minutes per day of production (also referred to the process TAKT).
      Ergonomic Requirements
       To minimize ergonomic risk and maximize operator efficiency as stated and
        observed by the National Institute for Occupational Safety and Health (NIOSH)
      Expendable versus returnable packaging
       System Sizing for returnable (or reusable) packaging
       Costs associated with expendable versus returnable packaging
      Part/Package Identification
      Information required to communicate requests properly




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REMY INC                                              PACKAGING CONTAINERIZATION


When to Evaluate Packaging and Containerization
Whenever a process is being evaluated for a new program or an established process is being
modified, packaging and containerization should also be evaluated. Many decisions can
impact packaging or containerization. The role of the packaging function is to support the
needed changes.

    New Product, Process or Program Development
      Part Presentation and packaging should be considered as early in the process
      development process as possible. Operator work envelopes may be optimized when
      evaluated prior to equipment design and build.

        The Pre-Production Part Approval Process requires that Production Trial Run parts be
        containerized in the defined production package. Therefore the package must be
        identified, tested and approved prior to receiving Final PPAP approval from Remy
        Inc.
    Process Re-engineering
       Typically process re-engineering is an enabler for efficiency improvements. The
       operators work envelope generally changes a great deal and the manner in which
       parts are presented or packaged greatly impacts the improvements that are realized.
    Process Re-location (within a facility or to another facility)
       The material movement requirement may change significantly when processes are
       relocated. The new area available may be much less, or have different material
       delivery systems. Although, within a facility may not affect the material handling
       requirement nearly as much as relocating the process over miles or continents. It is
       very important to not overlook how even a minor relocation may affect packaging.
    Due to an Ergonomic Concern
      Ergonomic evaluations or questionnaires often surface potential ergonomic risk
      factors in a workplace. Generally, extended reaches with even minimal weight may
      cause problems. Therefore based on force, frequency and posture, containers must be
      within certain sizes, weights and distances as noted in the workstation guidelines and
      manual material handling guidelines shown.

The MSD Process (Manufacturing System Development), specifically the Design activity
provides thought processes for designing part presentation devices too properly support the
operator. Proper packaging is critical to the success of manufacturing as we improve
operator efficiency and minimize work areas.




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REMY INC                                               PACKAGING CONTAINERIZATION


Guidelines for Decision Making
The safety of all associates at Remy Inc and associated supplier facilities is our highest
priority. The consideration of human movement and tolerances to fatigue must be given
priority when developing any packaging or material handling systems to prevent injuries and
accidents. All packaging must be in compliance with Remy Inc Ergonomic Standards. There
are many aspects of ergonomics and their relationship to packaging.

Choosing the appropriate container to support the operator
Choosing the appropriate container begins with determining the proper part orientation to the
operator. The workstation design and material handling procedures generally drive the part
package. Decisions are made based on ergonomic guidelines for parts presentation height and
reach, and manual material handling.

For example: The following are part presentation height and reach guidelines regarding
standing workstation design. All standing workstation part presentation should be designed to
fall within the guidelines wherever possible.




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REMY INC                                                                       PACKAGING CONTAINERIZATION



ERGONOMIC GUIDELINES – Standing Work
Typical Repetitive Work Height
  North American                        European                           Asian               Latin American
38 - 42 in (97-107 cm)            38 – 42 in (97-107 cm)            35 – 39 in (89-99 cm)   36 – 40 in (91-101 cm)

Parts Presentation Height and Reach
Maximum Shelf Height  2.0 lb. (0.9 kg)
     North American                     European                            Asian               Latin American
     48.0 in (122 cm)                48.0 in (122 cm)                 43.5in (110.5 cm)         46.5 in (118 cm)
     Accommodates the smallest female.
     Measured from the foot to the shoulder (Not the floor).
     Anything less than 2 lb. (0.9 kg) can be placed without restriction.

Minimum Height in Inches (All Material Handling)
     North American                     European                            Asian               Latin American
     21.5 in (54.5 cm)               21.0 in (53.5 cm)                  19.0in (48 cm)          20.0 in (51 cm)
     Accommodates the largest male.
     Weight is not considered.

Optimal Target Presentation Height by Weight
       Weight              North American                European                  Asian          Latin American
         2 lb.              40.0 – 50.0 in            40.0 – 50.0 in          37.0 – 46.0 in       39.0 – 47.0 in
       (0.9 kg)            (101.5 – 127 cm)          (101.5 – 127 cm)          (94 – 117 cm)       (99 – 119 cm)
        10 lb.               35.0 – 45.0in            35.0 – 45.0 in          33.0 – 41.0 in       34.0 – 43.0in
       (4.5 kg)              (89 – 114 cm)             (89 – 114 cm)          (84 – 104.5 cm)     (86.5 – 109 cm)
        10 lb.              29.0 – 39.0 in            29.0 – 39.0 in          34.0 – 43.0 in       29.0 – 38.0 in
       (4.5 kg)             (73.5 – 99 cm)            (73.5 – 99 cm)          (86.5 – 109 cm)     (73.5 – 96.5 cm)
     The range approximates the smallest female and the largest male.


One Handed Maximum Reach Distance
Distance from                                                 Height Above Floor
  Centerline               40 in (101.6 cm)           50 in (127 cm)    60 in (152.4 cm)         70 in (177.8 cm)
 12 in (30.5 cm)           18.0 in (46 cm)           22.0 in (56 cm)    22.0 in (56 cm)         16.0 in (40.5 cm)
 18 in (45.7 cm)           15.0 in (38 cm)           18.0 in (46 cm)    18.0 in (46 cm)         14.0 in (35.5 cm)
 24 in (60.9 cm)          10.0 in (25.5 cm)         14.0 in (35.5 cm) 14.0 in (35.5 cm)         8.0 in (20.5 cm)
 30 in (76.2 cm)            4.0 in (10 cm)           8.0 in (10 cm)      6.0 in (15 cm)          4.0 in (10 cm)
     No difference between men, woman and nationality.
     Centerline is from the center of the body outwards (right to left).
     Distance is measured from table edge.

Two Handed Maximum Reach Distance
    Distance from                                      Height Above Floor
      Centerline           40 in (101.6 cm)    50 in (127 cm)     60 in (152.4 cm) 70 in (177.8 cm)
  6 in (15.2 cm)           15.0 in (38 cm)    20.0 in (51 cm)     20.0 in (51 cm)    16.0 in (40.5 cm)
 12 in (30.5 cm)           11.0 in (28 cm)    15.0 in (38 cm)    14.0 in (35.5 cm)    11.0 in (28 cm)
 18 in (45.7 cm)            7.0 in (18 cm)   12.0 in (30.5 cm)    13.0 in (33 cm)     8.0 in (20.5 cm)
 18 in (45.7 cm)              Can not reach beyond 18 in (45.7 cm) from centerline with two hands.
     No difference between men, woman and nationality.
     Centerline is from the center of the body outwards (right to left).
     Distance is measured from table edge.
REMEMBER: You have a 10 by 10 inch (25.4 by 25.4 cm) optimum work area, 4 inches
(10.1 cm) out from the operator. As weight and frequency increase, minimize the reach
and move closer to the optimal target presentation height.

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REMY INC                                                  PACKAGING CONTAINERIZATION



Similarly, ergonomic requirements for manual material handling include the package size,
weight, location and degree of handles, the lift location from and to, the posture for the person
lifting and the frequency of the list in question. It should be noted that ergonomic acceptance
is always improved when proper handles or hand holes are designed into containers.

The following chart is meant to be a quick reference for Remy Inc and its suppliers in their
design and proposed containerization. During the initial test of packaging sent to Remy
ergonomics will be evaluated.


The following is a VERY BASIC AND GENERAL SET OF GUIDELINES FOR
MANUAL MATERIAL HANDLING.




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REMY INC                                               PACKAGING CONTAINERIZATION


      Acceptable Hand Held Container Weight Guidelines
                Adherence to MAXIMUM ALLOWABLE WEIGHT LIMITS
                     will substantially reduce the risk of employee
              injury and illness from manual material handling activities,
                      but can not guarantee complete prevention.
Assumptions
    One person performing material handling.
    No twisting at the waist.
    Optimal handle or handhold design. Frontal length = hand to hand distance.
    Average employee (Male or Female).
    No material handling (lifting) below 20 in (50.8 cm) from the floor.
    No material handling (lifting) above 70 in (177.8 cm) from the floor.
    Lifts performed throughout an 8-hour shift.
 LIFT DISTANCE
                  Between 20 in (50.8 cm) to 35 in (88.9 cm) from floor
   (Start/Finish)
FRONTAL LENGTH                   FREQUENCY OF LIFT
 OF CONTAINER      0.2/ Minute 1 / Minute    5 / Minute    10 / Minute
       25  x  20 in         32 lb.         28 lb.        15 lb.        5 lb.
    (63.5  x 50.8 cm)     (14.5 kg)      (12.7 kg)      (6.8 kg)    (2.26 kg)
       20  x  15 in         40 lb.         35 lb.        17 lb.        6 lb.
    (50.8  x 38.1 cm)     (18.1 kg)     (15.87 kg)      (7.7 kg)     (2.7 kg)
       15  x  10 in         40 lb.         40 lb.        22 lb.        8 lb.
    (38.1  x 25.4 cm)     (18.1 kg)      (18.1 kg)     (9.98 kg)     (3.6 kg)
           X 10              40 lb.         40 lb.        33 lb.       12 lb.
       (X 25.4 cm)         (18.1 kg)      (18.1 kg)    (14.97 kg)     (5.4 kg)
                                  MAXIMUM ALLOWABLE WEIGHT
 LIFT DISTANCE              Between 20 in (50.8 cm) to 70 in (177.8 cm) from
   (Start/Finish)                                floor
FRONTAL LENGTH                          FREQUENCY OF LIFT
 OF CONTAINER              0.2/ Minute   1 / Minute    5 / Minute   10 / Minute
       25  x  20 in          20 lb.        18 lb.         9 lb.        3 lb.
    (63.5  x 50.8 cm)       (9.0 kg)      (8.0 kg)      (4.0 kg)    (1.36 kg)
       20  x  15 in          26 lb.        23 lb.        11 lb.        4 lb.
    (50.8  x 38.1 cm)     (11.79 kg)     (10.4 kg)     (4.99 kg)     (1.8 kg)
       15  x  10 in          35 lb.        31 lb.        14 lb.        6 lb.
    (38.1  x 25.4 cm)    (15.87 kg)      (14.0 kg)     (6.35 kg)     (2.7 kg)
           X 10               40 lb.        40 lb.        22 lb.        8 lb.
       (X 25.4 cm)          (18.1 kg)     (18.1 kg)     (9.98 kg)     (3.6 kg)
                                  MAXIMUM ALLOWABLE WEIGHT

                                  WARNING
    Lifting that does not meet the assumptions listed above may have
    substantially reduced acceptable weight limits. You should consult
           your local Health & Safety professional for assistance
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REMY INC                                                  PACKAGING CONTAINERIZATION


Information Required to Begin Product Quotation
Determining the proper product package to support the operator must be accomplished prior
to engaging the purchasing organization and the supplier. Regardless of a new product, a
sourcing activity, or a change to a current package, the package requirement must be supplied
to the commodity manager for the RFQ package. At a minimum, determining the
appropriate part orientation to support the operator, the maximum number of parts
due to ergonomics and any part quality considerations, must be supplied. This
information is critical in determining the proper part quotation and enabling a clean total
product cost model to be analyzed. Total product cost includes the product, packaging,
transportation, and any additional activities that must occur between the supplier‟s facility and
ours.


The basic information supplied on the Packaging Change / Origination sheet includes:
    Part Number and Description
      Single Part Size and Weight
      Part Orientation to Support the Operator
      Container Guidelines
       Maximum or Recommended Pieces per Container
       General Container Size Required or Recommended
       General Container Weight Expected (Maximum)
      A Sketch of the Container Suggested
      A Sketch of Inserts Suggested
      Notations of any Special Part Protection required

The supplier‟s responsibility is to respond with a more specific recommendation, which
includes the container size, insert Drawings, and pallet size. Following initial agreement
between the supplier and Remy further definitions may be completed.

Utilize the Expected Savings table to denote improvements to the system due to the packaging
change. Place check marks in the categories that apply. Explain other in the additional notes
area.
        S – Safety
        $ – Enter $ Value
        E – Ergonomic
        O – Other




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REMY INC                                                 PACKAGING CONTAINERIZATION


           Packaging & Containerization Change / Origination
Please mark one:         Change      Origination                     Date:

Part description                                    Originator of Request:
Part number                                         Phone:
Part weight
Part Dimensions                                     Product Annual Vol:
Supplier                                            Supplier Location
Usage Department                                    Usage Location

                                                                                    Expected Savings
                                Current                       Proposed              S     $    E   O
Container Type
Container size
Full container weight
Part orientation
Quantity /container
Shipping frequency

                        Utilize this area for sketches or pictures




Quality Issues /
Additional Notes:


Remy Approvals
Tech Manager:                                         Production Control:
Continuous Improvement Engr:                          Quality Engr.:

Tracking                                              Packaging:
Purchasing:                                           Purchasing Notify Supplier:
Supplier returned:                                    SQA Filed:
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REMY INC                                                PACKAGING CONTAINERIZATION


Making Container Decisions
First the parts presentation requirements must be defined, then the package may be designed.
Based on the part size and maximum allowable pieces per container (or workstation
configuration) a general container size is decided upon. Chose the closest container size from
the standard container menu and begin. Any interior dunnage for part protection or stability
in the pack must be defined and sized appropriately to fit the container. Following the
container and interior dunnage decisions, chose a standard pallet. The standard container
menu includes containers that are modular with a standard pallet and top cap combination.
Seat belt options are preferred with the standard modular sets to eliminate the need for
additional banding or plastic wrap equipment. Please note there are corrugated equivalents to
all returnable modular containers. In the event that a returnable container is not the
appropriate solution, the corrugated equivalent may be utilized.

Interior Dunnage
Interior dunnage may be necessary to prevent part to part contact and damage. This dunnage
may be expendable or returnable. Only dunnage that has been approved by Remy Inc
Logistics may be used. There is no assurance that non-approved returnable dunnage will be
returned. All interior dunnage should be designed in a way to adequately protect the part
while maximizing part accessibility, minimizing waste and cost.
 Advance approval is required from DR for the use of non-recyclable expendable dunnage.
Returnable Containers
Returnable containers include modular returnable containers such as plastic totes, pallet
boxes, and plastic pallets; wire mesh baskets used primarily for containment of metal
stampings and “special” containers such as racks, carts, vacuum formed tray packs and sleeve
packs.
   Remy Inc intends to standardize to a minimal list of returnable containers for system ease.
    In doing so, any containers that do not conform to the standard container menu will be
    evaluated.

Special Returnable Containers
Special Returnable containers are to be used only if a standard modular container is not an
acceptable alternative. Special Returnable containers are containers providing special
containment for unique parts. Size, shape, configuration, weight or special handling at Remy
Inc‟s facilities determines the need for special packaging. Special returnable containers are
developed specifically for one part type only. These special returnable containers are not used
for any other parts.
    Remy Inc expects the supplier to be the project manager when a special returnable
    container is required.

All decisions and iterations must be documented on the Packaging Sketch Form provided.




For Reference Only                        PC – 20                           REV 11/23/2011
REMY INC                                                PACKAGING CONTAINERIZATION


Assignment
 The quantity of returnable containers assigned to the system will be agreed upon between
   Remy Inc and the supplier. The container assignment is an important tool in maintaining
   part inventory levels between Remy Inc and the supplier.
   Expected container inventory levels are to follow the Material/Container Flow Model,
    including both empty and full containers. This includes containers at the supplier, at the
    consolidation center, at Remy Inc and in-transit.

   If additional returnable containers are requested by the supplier, then supplier should
    address these requests in letter form directly to the Remy Inc Commodity Manager.

 Remy Inc will supply no additional returnable containers for special situations requiring
  additional safety stock to be held.
   No additional returnable containers will be provided due to inclement weather.


Damaged Remy Inc Modular or Special Returnable Containers
   Although Remy Inc retains ownership of the special returnable containers, suppliers are
    responsible for preventative maintenance and minor repairs.
   Damaged special containers must be identified by the using parties.
   All repairs will be completed by the supplier or a Remy Inc designated repair source.

Expendable Containers
 All domestic expendable packaging must be designed in a way that allows complete access
  to parts and eliminates the necessity to cut box tops open.
 Any methods used for securing box tops must not require cutting to gain access to parts.
  Tape is the preferred method for closure.
 Pallets must not be smaller in length and width than the load. No packaging materials may
  overhang the pallet
 Pallet construction and quality must be adequate to support the load weight and handling
  requirements
 Pallet dimensions should conform to the Remy Inc standard palletized unit.
 All pallets must have four way fork entry and minimum opening of 2-3/4 in. high x 9 in.
  wide. (Check these dimensions)
 All expendable packaging must be secured to pallets by either non-metallic strapping (at
  least two bands lengthwise and two bands widthwise) or by stretch wrap. All stretch wrap
  must be attached to the pallet and overlap the pallet to prevent loads from shifting in-
  transit. Stretch wrap must be transparent to allow visibility of labels. Stretch wrap
  fastened to a pallet leaving loose ends is not acceptable
 No steel Remy Inc supplied cases (KD cases) or pallets are permissible for shipping to
  Remy Inc Plant unless requested by Remy Inc Logistics.
For Reference Only                       PC – 21                           REV 11/23/2011
REMY INC                                                      PACKAGING CONTAINERIZATION



Export Considerations
    In general, the packaging sections of these guidelines apply to domestic and export
    packaging (ex.: ergonomics, labels, supplier development and responsibilities, etc.). Below
    are some specific considerations that must be incorporated into export package
    development.
 Packaging materials must be able to endure extreme conditions in several transportation
  modes (truck, rail, and ship) and protect parts from vibration and moisture. The expected
  endurance period is four months. Please note some service part applications may require
  additional shelf life package applications.
 for example: To ensure the quality of small size metal/machined parts, these parts need to
  be coated with an anti-rust solution, placed in a carton box, lined and sealed with rust
  preventative sheeting. Small weld component parts may also be packed in poly weld bags.
 All export packaging must be designed to maximize cube efficiency. The package should
  fit the part at the specified quantity with no extra space.


Returnable Container System Sizing
For Returnable container consideration, the system (or loop) size must be determined. Follow
the Container Flow Worksheet to the right for system sizing. It is critical that the complete
system be understood, the consumption rate, the ship frequency of containers full of product,
the ship frequency of empty containers back to the supplier, etc… In addition, it is very
important to understand the actual shipping and transportation method. The time required for
the container to “ride” with a logistics carrier from the time it leaves one dock and arrives at
the other is the length of transit. Note: this is NOT just the drive or fly time under perfect
conditions. Many shared trucks stop multiple times from one dock to the next and it is
important to account for actual travel time.

Material Container Flow Model for a Seven Day System
Allocation Example Based On:     Production = 600 / day               Package Quantity = 60 pieces
                                                                      Containers per day = 10
                                        RETURNABLE
                                      CONTAINER CENTER
                                              10 Containers
                                  1 Day Total
                                      0.5 In House
                                      0.5 In Transit From Remy Inc
                                                                                   REMY INC
         SUPPLIER                                                                   5 Containers
          40 Containers
                                                                               0.5 Days Productions
    1 Day Production
    2 Days Finished Goods                 Consolidation
    1 Day In Transit
                                             Center
                                            15 Containers
                                    1.5 Days Staging for DR



For Reference Only                         PC – 22                             REV 11/23/2011
REMY INC                                                             PACKAGING CONTAINERIZATION


                CONTAINER FLOW WORKSHEET
For Product #                                 Description
Supplier Name
Ship     From:                                                  Ship Frequency
Location             City, State, Country                                                   Daily, Weekly, Monthly

         To:                                                    Return Empty Frequency
                                                                                            X/hour, x/Day, X/Week


Transit:   Carrier                                       Length of Transit    To:
           Type                                                               From
                     Milk Run, LTL, Dedicated Truck


                                  Container Allocation By Location
       Supplier                              In Transit                              Customer
        Days Full                           From Supplier Full                      Hr/Days Full
        Days Empty                                                                  Hr/Days Empty
        OT Days/hrs                                                                 Total Days/hours
                                            From Customer
                                            Empty
Repair Factor %
       Days

System Size Calculations
Container ID:                        A                   A2                  A3                   A4
                                     1
  VOLUMES
  Parts/Day                          B
  Parts/Container                    C
  Containers/Day                     D

        SYSTEM SIZE
      CALCULATIONS
  Supplier Full                      E
  Supplier Empty                     F
  Customer Full                      G
  Customer Empty                     H
  Transit Time To                    I
  Transit Time From                  K
  Total Days Req'd                   J
  Containers/Day                     L
      Number of Containers

Remy Approvals
Production Control:                                           Manufacturing Engr:
Continuous Improvement Engr:                                  Packaging Engr:
Submitted to Purchasing:

For Reference Only                                    PC – 23                            REV 11/23/2011
REMY INC                                                 PACKAGING CONTAINERIZATION


Container Flow Worksheet Instruction
  Item   Description

  A.     List the container ID number (and description if desired) that is being specified as
         the container for the product described. One or more items may comprise a pack.
         (e.g. tray in a tote on a pallet)

  B.     List the daily product rate for the product described.

  C.     List the quantity of product that will be packed in the container described in Item
         A.

  D.     Divide Item B by item C and write in the answer here. This is the total number of
         containers that are used daily to pack the product.

  E.     Full containers required by the supplier. (Listed in Item F)
         .
  F.     Empty containers required by the supplier. (Listed in Item H)

  G.     Full containers required by the customer. (listed in Item L)

  H.     Empty containers required by the customer. (Listed in Item N)

  I.     Full containers in transit to the customer from the supplier. (Listed in Item I)

  J.     Empty containers I transit to the supplier from the customer. (Listed in Item K)

  K.     Total number of days that are required to support the production and shipping
         system for the product described in Item A. Add items S, T, U, V, W, and X and
         enter the sum here.

  L.     Write in the number of containers used daily, which was calculated in Item R.

  M.     Number of containers required to supply the production/shipping program for the
         product described. Multiply item K by Item L and enter the answer here.




For Reference Only                        PC – 24                            REV 11/23/2011
REMY INC                                             PACKAGING CONTAINERIZATION


Returnable/Expendable Packaging Cost Analysis
It is very important to investigate the cost of the TOTAL returnable system versus the
expendable system. Comparing the container cost alone is not adequate. To make educated
container decisions the following information must be compiled:

      Cost of the following
       expendable container
       returnable container
       inserts / internal dunnage
       pallet
       pallet banding or stretch wrap
       transportation
      Size of returnable container system
      Any special costs, i.e.
        tooling
        re-packaging
       removal of any non-recyclable material
       etc.

Utilize the following worksheet for a comparison of expendable and returnable packaging.
The output includes Return on Investment and payback period. The following example is
initially rejected due to the cost of returnable containers alone. However, the total cost
analysis shows the positive impact on the operation. The payback period is less than 6
months. The operation has approved the implementation of the returnable container for this
product.




For Reference Only                       PC – 25                        REV 11/23/2011
REMY INC                                                          PACKAGING CONTAINERIZATION


                         Returnable Packaging Cost Analysis
      Cost of Expendable Packaging:                                                     Totals
1)    Number of cartons/week (Including Dunnage):                                                          400
2)    Cost of Carton (and dunnage if applicable)                                                           5.25
3)    Annual Carton and Dunnage Cost (1 x 2 x 52 = Cost)                                                109200
4)    Number of pallets / week:                                                                              20
5)    Cost / Pallet:                                                                                          9
6)    Annual Pallet Cost:(4 x 5 x 52 = cost)                                                              9360
7)    Total Expendable Packaging Cost:(3 + 6 = total)                                                   118560
8)    Transportation Costs for the Product Shipments / Week:                                               500
9)    Total Trans. Cost for Expendable Products shipping:(8 x 52 = cost)                                 26000
10)   Total Annual Expense for Expendable pkg. Use:(7 + 9 = Total)                                      144560

      Cost of Returnable Packaging:
11)   Number of Containers Required to Fill System:                                                        800
12)   Cost / Container (include dunnage if applicable):                                                     25
13)   Total Container Cost(including dunnage): (11 + 12 = total)                                         20000
14)   Number of pallets Required for System:                                                                40
15)   Cost / Pallet(include top cap if applicable):                                                         75
16)   Total Pallet Cost: ( 14 x 15 = total)                                                               3000
17)   Total Returnable Packaging Costs: (13 + 16 = Total)                                                23000
18)   Transportation Cost for Product Shipments / Week:                                                    400
19)   Total Trans. Cost for Returnable Products Shipping: (18 x 52 = cost)                               20800
20)   Trans. Cost for Product Returns / Week:                                                              400
21)   Total Trans. Cost for Returnable Products Returns: (20 x 52 = cost)                                20800
22)   Total Annual Returnable Packaging / Trans. Cost: (17+19+21=total)                                  64600

      COMPARISON : EXPENDABLE VS RETURNABLE PACKAGING

       Accelerated Cost Capital Investments Annual Expendable          Returnable       Returnable container
       Recovery System for returnable cont.     Expense                Container           Total Savings
           (ACRS)                                                       Expense           (Before Taxes)
           3 Years                                 (A)                    (B)                   (C)

         year 1 ….25%               $64,600.00         $144,560.00         $16,150.00            $128,410.00
         year 2 ….38%                                  $144,560.00         $24,548.00            $120,012.00
         year 3 ….37%                                  $144,560.00         $23,902.00            $120,658.00

      Totals                        $64,600.00         $433,680.00         $64,600.00            $369,080.00

      RETURN ON INVESTMENT:                                          PAYBACK PERIOD

      Three year savings, returnable vs Expendable                   (Total of 22 / total of 10)*12 = months

              433,680.00             64,600.00          369,080.00                               5.36
             Total              Returnable             R.O.I.
          Expendable             Container
           Expense               Expense
                               (3 year cost)
For Reference Only                               PC – 26                                  REV 11/23/2011
REMY INC                                                 PACKAGING CONTAINERIZATION


Logistics Decisions

Transportation
 In cases where Remy Inc will pay the carrier directly, the transportation cost must not be
  included on the Procurement and Logistics Quotation Forms.
 When developing special returnable containers, it is important that the special returnable
  containers are designed to maximize trailer efficiency and to minimize transitional shifting.
 It is the supplier‟s and carrier‟s responsibility to ensure that carrier‟s equipment is safety
  and efficiently loaded in a live load situation. In a drop and hook scenario, the
  responsibility lies 100% with the supplier.
    Material must not be forced into a trailer so that packaging or carrier equipment is
    damaged. Suppliers will be responsible for any damage they cause to carrier‟s equipment.
    Sufficient clearance must be maintained to permit easy unloading.
 All parts and material must be palletized or in returnable containers for shipping, unless
  approved by Remy Inc Logistics. Material must be loaded in a manner to permit unloading
  by industrial lift trucks.

 All pallets and returnable containers must be loaded and braced to prevent shifting in-
  transit. No bracing materials are to be nailed to the floor or walls of trailers to secure the
  load without prior approval. Load bars and strapping are appropriate methods for securing
  loads.
 Heavy unit loads or unlike sizes must not be stacked on lighter loads.
 If a supplier damages a carrier‟s equipment or receives a trailer in poor condition, it must
  be reported immediately to the carrier. Unreported damage could jeopardize the quality of
  parts and material.
 Live loading should be handled in an expeditious manner. Waiting time for the carrier
  must be kept to an absolute minimum. Carrier detention rules will specify free time
  allowances and charges for waiting time. It is the supplier‟s responsibility to pay any
  applicable detention charges that occur at their facility.

Part Combination
 Parts may only be mixed on pallet as specified.
 Only one part number may be packed per container.
 Parts manufactured to different design change levels must not be mixed in the same
  container or on the same pallet.




For Reference Only                        PC – 27                           REV 11/23/2011
REMY INC                                                PACKAGING CONTAINERIZATION


Labels
   All containers shipped to Remy Inc must have container labels. This conforms to the
    Automotive Industry Action Group (A.I.A.G.) B10 Standards.
 Part number, quantity, supplier name and serial number are mandatory fields and must be
  included in both human readable and bar code form. Part number and part level must
  conform to what is actually in the container. See Example Label below.




 All individual containers are required to have a supplier label securely attached to them.
  These are small labels that will be necessary for our in-plant and on-line personnel to
  properly identify each container and the parts they contain.

 When a returnable container is used it is required that those containers have a placard
  containment bracket or some similar apparatus that provides a reliable location for labeling
  and insures that the label may be easily removed before the container is used again




For Reference Only                       PC – 28                           REV 11/23/2011
REMY INC                                                PACKAGING CONTAINERIZATION


 Two standard AIAG shipping labels are required, one label on opposite sides of each load
  facing the pallet opening in the upper right hand corner. The labels must be in plain view
  so that the fork lift operator can easily see and identify the load without dismounting the
  truck.
 Special labels are to be applied directly below part identification labels. Examples of
  special labels are EXPORT, SERVICES PARTS, and INITIAL PRODUCTION PARTS
  (IPP). Part identification labels must be visible after containers have been palletized for
  shipping.
 Suppliers using stretch wrap must apply sequence and pre-production lot labels under the
  stretch wrap.
 Any parts packaged in bags, must be include a label on the bag identifying the supplier, part
  number, quantity and color in human readable form. Remy Inc Logistics will specify
  special cases that may require each part to be labeled.
 Any pallet with more than two container labels with the same part number shall use a
  Master Label. Any pallet with more than two containers and different parts numbers must
  use a Mix Label.
 All suppliers are required to complete and return the Part Package and Transportation
  Detail Form outlining packaging information and cost. A Packaging Sketch Form must
  accompany the Part Package and Transportation Detail.

Documenting Container Systems
Each container system must be completely documented. The Packaging Sketch Form MUST
accompany the Part Package and Logistics Detail Form. The packaging sketch form captures
the part to be packaged, the dunnage required in the pack, the container drawing and
specifications and the overall pallet pack drawing. Please note the four quadrant boxes.

   1. Part drawing or Photograph – The part being packaged that will be presented to the
      operator for use.
   2. Dunnage drawing or photograph – The layer pads or sectioned dividers being used to
      protect the part (if applicable)
   3. Container drawing photograph – The physical container, dunnage if applicable and a
      visual showing how the part is to be placed in the container.
   4. Overall packaging drawing or photograph – The entire skid or shippable package as
      received by the facility.

The Part Package and Transportation Detail form captures all the detail behind the sketch
form and the general transportation information. This includes: part specific detail, exact
container dimensions and weight, detailed package costs, carrier and ship frequency
information. Both the Packaging Sketch form and the Part Package and Transportation Detail
forms are filed with the Supplier PPAP file. Each must remain up to date at all times.




For Reference Only                       PC – 29                            REV 11/23/2011
REMY INC                                                                           PACKAGING CONTAINERIZATION




                                          PACKAGING SKETCH FORM
                                                  PART NUMBER:_________________________________
                                                  PART NAME:____________________________________
    SUPPLIER:____________________________________ DATE ISSUED:__________________________________
    PACKAGING CONTACT:________________________ REVISION NUMBER:_____________________________
    SIGNATURE:__________________________________ MODEL & TYPE:_________________________________
    CONTACT PHONE:_____________________________ FINAL APPROVAL DATE: _________________________
    1. Part Drawing or Photograph                 2. Dunnage Drawing or Photograph




    Part weight: ______________________________                  # of pcs of dunnage per container: ___________
    Part dimensions: __________________________                  circle one: returnable/expendable dunnage
    3. Container Drawing or Photo                                4. Overall Pack Drawing or Photo




                                                                 # of Containers per Pallet: __________________
    Type of Container: _________________________                 Pallet Type: Returnable or Expendable
    Quantity of Parts per Container: ______________              Pallet Dimensions: ________________________
    Loaded Gross Weight: _____________________                   Gross Weight: ___________________________
    Container Dimension: ______________________                  Overall Pack Dimensions: __________________

    NOTE: Complete all sections that apply. Due to the high importance of acceptable packaging, final package acceptance
    will not be given prior to one month after full production start-up. Only approvals received in writing from Delco Remy are
    considered valid.
    DR APPROVALS
    Technical Manager:                                           Production Control:
    Continuous Improvement Engr:                                 Quality Engr:




For Reference Only                                          PC – 30                                             REV 11/23/2011
REMY INC                                                                                 PACKAGING CONTAINERIZATION




                                                                   SKETCH FORM PART PACKAGE AND
                                                                     TRANSPORTATION DETAIL
Ship to Location:                                                                           Ship From Location:

ADDITIONAL PART DATA
Preservatives:(desiccants, oil coatings, layers, etc)

PACKAGING DATA                                     Bulk       Small Lot (circle one)
Returnable Container Type:                                                 Expendable Container Type: Carton / Pallet Box / Other:
Internal Dunnage:                                                          Material: 1 Wall 2 Wall 3 Wall Other:
Outside Dimensions: (in / cm) L             W          H                   Outside Dimensions:L         W           H
Pallet Dimensions (in / cm / m) L            W         H                   Pallet Dimensions: L         W           H
Loaded weight Parts + Container (LB / kg):                                 Loaded Weight (LB Part + Container)
Qty/Container:           Qty/Pallet:            Pallet weight:             Qty/Container:             Qty/pallet:
Double stackable: yes / no                                                 Double stackable: yes / no

COMMENTS:




Container Ownership:DR                 %      Supplier              %                       Special Instructions:
Amortization: # of years:                  # of parts/year:             Is packaging included in pcs. price: Yes / No (circle one)

PACKAGING COST DATA                                    CURRENT                  NEW         NEW
                                                       (cost/part)          (cost/part) Cost per (1) item
Carton                                                                                      Carton:
Interior Dunnage                                                                            Set of Dunnage:
Pallet                                                                                      Pallet:
Stretch Wrap / Banding / Belts (circle)                                                     Stretch Wrap / Banding / Seat Belts:
Labels (material only)                                                                      (1) Container label:
Other (please specify)                                                                      (1) Ship label:
Other (please specify)
Total packaging cost for one part ($)                                                       Cost Difference: $
Cost information completed by(Name & Phone #):


Transportation Data
Carrier Name:
Shipping Frequency: Day        Week        Month    Other________        Miles Traveled per trip: One Way / Round Trip

DR APPROVALS
Tech Manager:                                                              Production Control:
CI Engr:                                                                   Quality Engr:
DR Packaging and Logistics:                                         Approval Date:                              Effective Date:
Return To: Delco Remy, Attn. Purchasing, 2902 Enterprise, Drive, Anderson IN. 46013
Questions: Contact Commodity Manager



For Reference Only                                                PC – 31                                               REV 11/23/2011
REMY INC                                                    PACKAGING CONTAINERIZATION


Sketch / Part Package and Transportation Detail Form Instructions
 Section              Description

 Supplier Name        Enter the name of the company supplying this part to Remy Inc.

 Model/Year/Type      Enter the model or models, year and type on which this part is used

 Part Number          Enter the Remy Inc part number as it appears on the part Drawing for the
                      quotation being submitted.

 Part Name            Enter the Remy Inc part description as it appears on the part Drawing.

 Date Issued          Enter the date this quotation is issued to the Remy Inc Logistics Group.
                      MM/DD/YY

 Ship To Location     Enter the exact name, City, State and Country of the facility this part is
                      shipped to.

 Ship From Location   Enter the city, state and Country in which the shipping facility is located.

 Supplier‟s           Enter the name and telephone number of the person at the supplier
 Packaging Contact    responsible for addressing all packaging issues.

 Part Dimensions      Enter the overall length, width, and height of the part.

 Finished Part        Enter the weight of one finished part.
 Weight

 Preservatives        Enter any part preservatives required, i.e. desiccants, oil, coatings, layers,
                      etc.

 Container            Complete either the returnable section OR the expendable section, only
                      one per form for quotation purposes

 Type of Container    Enter the type of Remy Inc Plant modular returnable container (if applicable)
                      used to ship this part. If other, please specify.

 Internal Dunnage     Interior to a single container (modular container / returnable or corrugated).
                      Specify not applicable, layer pads, divided, etc…

 Outside Dimensions   Enter the length, width, and height dimensions, for the container specified

 Pallet Dimensions    Enter the length, width and height dimensions for the pallet

 Loaded Weight        Enter the total weight in pounds of all parts and packaging, which comprise
                      a single container of parts ready for shipment.

 Qty / Container      Enter the number of parts packed in a single returnable container.

 Qty / Pallet         Enter the number of parts packed on a full pallet load.
 Pallet Weight        Full shippable pallet weight

 Double Stack         To specify if double stacking in transit is permissible. In some packaging

For Reference Only                         PC – 32                                REV 11/23/2011
REMY INC                                                   PACKAGING CONTAINERIZATION

                      selections, double stacking is NOT allowed due to part quality concerns,
                      package strength for bottom pallet, etc… Circle yes or no for the container
                      configuration being quoted.

 Returnable only      Complete this section only if returnable packaging is being quoted on this
                      form.

 Container            Enter the percentage of returnable container ownership cost for which each
 Ownership            party, Remy Inc and the supplier, will be responsible.

 Amortization         Enter amount agreed upon for special packaging payment over a specific
                      amount of production. Indicate whether or not packaging is included in
                      piece price (circle one)

 Packaging Cost       Enter current and new costs, and cost differences, in dollars, as outlined
 Data                 for each item. Enter as cost per item to far right and cost per part.

 Carton               The single container item

 Interior Dunnage     Internal to the single container

 Pallet               The wood / disposable Pallet or the returnable Pallet and Top cap pair

 Banding              stretch wrap or banding or “seat belts” if applicable. Circle appropriate
                      method

 Labels               Labels for the entire pallet should be considered. Individual container labels
                      as well as shipping labels.

 Other                Please explain any other packaging cost factors in detail. Use additional
                      sheets if necessary

 Total Packing Cost   Enter the total packaging cost for one part, as it appears on the Component
 for One Part         or Fabricated part Quotation Form provided to the Cost Procurement Group.

 Cost Information     Enter the name and telephone number of the person supplying the cost
 Completed By         information.

 Transportation
 Data

 Carrier Name         Enter the name of the carrier specified by Remy Inc Logistics.

 Shipping Frequency   Enter the number of times freight will be shipped and circle appropriate
                      frequency per day, week, or month.

 Miles Traveled       Enter the number of miles between the shipping origin and “ship to”
                      location.

 Remy Inc Packaging   Remy Inc Logistics will complete this section.
 and Logistics




For Reference Only                         PC – 33                               REV 11/23/2011
REMY INC                                                  PACKAGING CONTAINERIZATION


Test Packaging
Following Container decisions, test packaging is ALWAYS required. Test packages ensure
that the interaction between the new package and the manufacturing process is confirmed.
Packaging should not be changed without first completing a successful test package.
Following the successful test package and the appropriate Remy Inc approvals, system
packaging / dunnage may be ordered.
    The test pack must be received well in advance of use of the supplier‟s product in the
     normal Remy Inc manufacturing process.
    The test package must exactly mimic the proposed container that will be used for the
     supplier‟s normal shipments to Remy Inc. After approval all future shipments must
     conform to the approved test pack specifications, as documented on the packaging
     sketch form.
    Any and all test packages sent to Remy Inc must have the test pack document
     attached on four sides with the information shown at right. This shipment is a
     requirement of the Remy Inc PPAP process.
    The test pack document must be at least 8.5 x 11 inches and be bright iridescent
     orange in color with contrasting print.
    Please note that as a supplier for Remy Inc you are responsible for all parts arriving at
     Remy Inc or a Remy Inc distribution center in a quality condition.
    Any damages due to packaging will be the responsibility of the supplier.
    Non-compliance or variation will result in a 5 Phase Corrective Action issued by Remy
     Inc Supplier Quality.
    Continuous non-conformances will be defined as a recurring problem and will be
     referred to Remy Inc Purchasing for further action.
    Charges incurred because of repackaging, disposal or production interruption will be
     billed back to the supplier shipping location.

The Supplier is responsible for notifying the receiving plant, of: the expected ship and arrival
dates for the test pack. The Materials Manager for the facility is the point of contact.
Remy Inc is responsible for routing the test pack and completing the approval information.
The test pack is to be routed through the facility to simulate production; i.e. removed from
truck with normal equipment, delivered via timed material delivery as applicable, etc. Any
deviations required from the normal material handling process must be noted and corrected if
applicable within the plant. If the deviation is due to a package issue, the plant is responsible
for rejecting the test pack were applicable.

Implementing the Package System
Following an acceptable test pack, it is the responsibility of Material Control for the
respective facility along with the supplier to establish dates, volumes, new standard pack
pulls, etc. and complete the implementation of the new package. It is also the responsibility
of Material Control to engage the Packaging Engineer regarding the purchase of any
returnable containers.

For Reference Only                        PC – 34                            REV 11/23/2011
REMY INC                                    PACKAGING CONTAINERIZATION




                         TEST PACK
   DO NOT USE PARTS FOR PRODUCTION PRIOR
             TO AUTHORIZATION!

     MATERIALS MANAGER:
                 PHONE:

   NOTIFY MATERIAL CONTROL UPON ARRIVAL

   Supplier:                              Contact:
      Part #:                              Phone:
  Ship Date:


TEST PACK ROUTING THROUGH FACILITY - OK
Arrived Good Condition                 Part Presentation for Op
Placed to Market                       Operator Remove Empty
Timed Delivery Load
Delivery to Rack
Plant Approvals                        Name                           Date
Materials:
Quality:
Operations:
Operations Support:
Comments:


Route completed form to Commodity Manager:_______________________
Initial:______    Date:____________

For Reference Only           PC – 35                        REV 11/23/2011
REMY INC                                               PACKAGING CONTAINERIZATION


CONCLUSION
Remy Inc is very interested in your success as our supplier and welcome any questions that
may arise concerning our packaging requirements. Please feel free to contract our Packaging
Department for further information.

                     Remy Inc America
                     Attn: Packaging Engineer
                     600 Corporation DR
                     Pendleton IN 46064
                     Ph. (765) 778-6453
                     Fx. (765) 221-6153

It is Remy Inc intention to create efficient and amiable relationships with our suppliers. A
major contribution to this end is good supplier/customer communications. For this reason this
information manual is included in your quote packet. Please read and use this information.
We at Remy Inc America are very interested in your success as one of our valued suppliers.

Note: This document will be updated and expanded upon as necessary. Revisions will be
distributed at that time.

Any current package, which does not comply with Remy Inc‟s standards (including, but not
limited to: container, ergonomics, safety, cost…) will be re-evaluated as appropriate.




For Reference Only                      PC – 36                           REV 11/23/2011
REMY INC                       PACKAGING CONTAINERIZATION




              Remy Inc
         Standard Container
               Menu




For Reference Only   PC – 37                 REV 11/23/2011
REMY INC                                                              PACKAGING CONTAINERIZATION


      Remy Inc Standard Container Menu – English Units


Schaefer Standard Straight Walled Containers- Crosstac Series
                                                              Inside Bottom     Inside
                          Outside Top Dimensions               Dimensions       Usable     Wt.     Nest
        Description        L”       W”      H”                  L”      W”        H”       Lbs.   inches

        AF 1207-5          12        7.4            5          9.3       5.3     4.3       1.3      .5

        AF 1215-4XC       11.9       15             4          9.4        13     2.9       2.2      .5

        AF 1215-7X         12        15            7.5         9.3       12.9    6.8       3.2      .5

        AF 2415-4XC        24        15             4         21.4        13     2.9       4.0      .5

        AF 2415-7C         24        15            7.5        21.4        13     6.4       4.9      .5

        AF 2422-7C         24       22.5           7.5        21.4       20.5    6.4       6.5      .5

Schaefer Standard Returnable Pallets
                                     Outside Top
                                     Dimensions                          Load Capacity              Wt.      Nest
    Product #   Description       L”     W”      H”                  Static       Dynamic           Lbs.    inches

AFP 4845        Pallet           48.75     45.75        6.0          30,000            4,000         38      .25

AFT 4845        Top Cap          48.75     45.75        1.5                                          20       .5


The Schaefer Crosstac container system was chosen because the footprints and heights can be
mixed and matched on a pallet in almost any order. Keep in mind:
        Two 4” boxes =           one 7” box
        Three 4” boxes =         one 11” box
        Four 4” boxes =          one 14” box
The AF 1207-5 container is included on our standard menu due to the lack of a 1207 container
in the Crosstac series and the popularity of the footprint in many of our facilities. As a 1207-4
Crosstac becomes available it will replace the 1207-5. There are also larger Crosstac
containers that may be required when packaging bulky, yet lightweight parts. Use careful
consideration with the larger containers. Typical Pallet height limit is 50” including the pallet
and top cap.
Schaefer Straight Walled Container- AIAG Fastener Tote
                                                              Inside Bottom     Inside
                          Outside Top Dimensions               Dimensions       Usable     Wt.     Nest
        Description        L”       W”      H”                  L”      W”        H”       Lbs.   inches

        AIAG0003          13.5      6.75           6.5        11.25      5.5      6        1.8      .5

For Reference Only                                 PC – 38                                 REV 11/23/2011
REMY INC                                                            PACKAGING CONTAINERIZATION


Remy Inc Standard Container Menu – English Units


Standard Corrugated Straight Walled Containers

                                   Outside Top Dimensions             Nest
                Description         L”       W”      H”               Ratio

                DR 1207-5           12           7         5           1:1

                DR 1215-5           12           15        5           1:1

                DR 1215-7           12           15        7           1:1

                DR 1215-9           12           15        9           1:1

                DR 2415-5           24           15        5           1:1

                DR 2415-7           24           15        7           1:1

Standard Wood Pallets
                                              Dimensions              Wt.
                     Description      L”         W”      H”           Lbs.

                190099723                40      44       4.4         35

                275846                   40      40       4.4         35

                190099726                48      40       5.5         35

                19099804                 48      45       5.5         35



ORBIS Collapsible Bulk Containers - Access Doors on 2 Sides
                                                                      Inside
                                                 Inside Bottom        Usable
                Outside Top Dimensions            Dimensions          Height   Wt.    Nest
 Description     L”       W”      H”               L”      W”           H”     Lbs.   Ratio

 32”x30”x25”     32         30        25         29.125        27      17.5    50     2.5:1

 32”x30”x34”     32         30        34         29.125        27      26.5    71     2.5:1

 48”x45”x25”   47.625     44.625    25.625       44.25     41.25       18.9    96     3.0:1

 48”x45”x34”   47.625     44.625      34         44.25     41.25        27     120    2.6:1


For Reference Only                             PC – 39                                REV 11/23/2011
REMY INC                                                          PACKAGING CONTAINERIZATION


   Remy Inc Standard Container Menu – Metric Units


Schaefer Standard Straight Walled Containers- Euro Fix Series
                                                        Inside Bottom       Inside
                       Outside Top Dimensions             Dimensions        Usable
                         L       W        H                L       W           H       Wt.        Nest
   Description         (cm)     (cm)    (cm)             (cm)    (cm)        (cm)      Kg.        (cm)

   EF3120               30         20         11.9      26.6      16.5       9.9       .5         1.27

   EF4120               40         30         12        36.5      26.5       10.1      .8         1.27

   EF4170               40         30         17        36.5      26.5       14.4      1          1.27

   EF6120               60         40         12        56.6      36.5       10.1      1.6        1.27

   EF6180               60         40         18        56.6      36.5       15.4      2          1.27



Schaefer Standard Returnable Pallets
                                        Outside Top
                                        Dimensions
                                      L     W       H             Wt.         Nest
     Product #       Description    (cm) (cm) (cm)                Kg.         (cm)

   EFP 4840         Pallet              120    100      15.5      17.24        .64

   EFT 4840         Top Cap             120    104      3.8        9.0        1.27



Schaefer Straight Walled Container- AIAG Fastener Tote
                                                          Inside Bottom       Inside
                         Outside Top Dimensions             Dimensions        Usable
      Description          L       W        H                L       W           H         Wt.      Nest
                         (cm)     (cm)    (cm)             (cm)    (cm)        (cm)        Kg.      (cm)

      AIAG0003           34.29      17.15       16.51     28.58     13.97     15.24         .82      1.27




For Reference Only                              PC – 40                                  REV 11/23/2011
REMY INC                                                         PACKAGING CONTAINERIZATION


Remy Inc Standard Container Menu – Metric Units


   Standard Corrugated Straight Walled Containers
                                    Outside Top Dimensions
                                      L       W        H            Nest
                Description         (cm)     (cm)    (cm)           Ratio

                DR 1207-5           30.48     17.78      12.7        1:1

                DR 1215-5           30.48     38.1       12.7        1:1

                DR 1215-7           30.48     38.1       17.78       1:1

                DR 1215-9           30.48     38.1       22.86       1:1

                DR 2415-5           60.96     38.1       12.7        1:1

                DR 2415-7           60.96     38.1       17.78       1:1

Standard Wood Pallets
                                          Dimensions
                                        L    W       H              Wt.
                     Description      (cm) (cm) (cm)                Kg.

                19099723              101.6    111.7    11.17     15.87

                275846                101.6    101.6    11.17     15.87

                19099726              121.9    101.6    13.97     15.87

                19099804              121.9    114.3    13.97     15.87


ORBIS Collapsible Bulk Containers - Access Doors on 2 Sides
                                                                      Inside
                                                 Inside Bottom        Usable
                 Outside Top Dimensions           Dimensions          Height
                   L       W        H              L        W            H      Wt.      Nest
  Description    (cm)     (cm)    (cm)           (cm)     (cm)         (cm)     Kg.      Ratio

  32”x30”x25”    81.28      76.2       63.5      73.98      68.58      44.45    22.7      2.5:1

  32”x30”x34”    81.28      76.2      86.36      73.98      68.58      67.31    32.2      2.5:1

  48”x45”x25”   120.98     113.34     65.09     112.39     104.77          48   43.5      3.0:1

  48”x45”x34”   120.98     113.34     86.36     112.39     104.77      68.58    54.4      2.6:1
For Reference Only                            PC – 41                                  REV 11/23/2011
REMY INC                          PACKAGING CONTAINERIZATION




                     Blank Forms




For Reference Only      PC – 42                 REV 11/23/2011
            Packaging & Containerization Change / Origination

Please mark one:        Change      Origination                  Date:
Part description                              Originator of Request:
Part number                                   Phone:
Part weight
Part Dimensions                               Product Annual Vol:
Supplier                                      Supplier Location
Usage Department                              Usage Location

                                                                                Expected Savings
                               Current                    Proposed              S    $    E      O
Container Type
Container size
Full container weight
Part orientation
Quantity /container
Shipping frequency

                        Utilize this area for sketches or pictures




Quality Issues /
Additional Notes:


DR Approvals
Tech Manager:                                     Production Control:
Continuous Improvement Engr:                      Quality Engr.:

Tracking                                          Packaging:
Purchasing:                                       Purchasing Notify Supplier:
Supplier returned:                                SQA Filed:
                                                                                REV 11/23/2011
                CONTAINER FLOW WORKSHEET

For Product #                                 Description
Supplier Name
Ship     From:                                               Ship Frequency
Location             City, State, Country                                                 Daily, Weekly, Monthly

         To:                                                 Return Empty Frequency
                                                                                          X/hour, x/Day, X/Week


Transit:   Carrier                                    Length of Transit     To:
           Type                                                             From
                     Milk Run, LTL, Dedicated Truck


                                Container Allocation By Location
       Supplier                              In Transit                            Customer
        Days Full                           From Supplier Full                    Hr/Days Full
        Days Empty                                                                Hr/Days Empty
        OT Days/hrs                                                               Total Days/hours
                                            From Customer
                                            Empty
Repair Factor %
       Days

System Size Calculations
Container ID:                        A                A2                  A3                    A4
                                     1
  VOLUMES
  Parts/Day                          B
  Parts/Container                    C
  Containers/Day                     D

        SYSTEM SIZE
      CALCULATIONS
  Supplier Full                      E
  Supplier Empty                     F
  Customer Full                      G
  Customer Empty                     H
  Transit Time To                    I
  Transit Time From                  K
  Total Days Req'd                   J
  Containers/Day                     L
      Number of Containers

DR Approvals
Production Control:                                         Manufacturing Engr:
Continuous Improvement Engr:                                Packaging Engr:
Submitted to Purchasing:


                                                                                               REV 11/23/2011
                     Returnable Packaging Cost Analysis
      Cost of Expandable Packaging:                                                       Totals
1)    Number of cartons/week (Including Dunnage):
2)    Cost of Carton (and dunnage if applicable)
3)    Annual Carton and Dunnage Cost (1 x 2 x 52 = Cost)                                                          0
4)    Number of pallets / week:
5)    Cost / Pallet:
6)    Annual Pallet Cost:(4 x 5 x 52 = cost)                                                                      0
7)    Total Expandable Packaging Cost:(3 + 6 = total)                                                             0
8)    Transportation Costs for the Product Shipments / Week:
9)    Total Trans. Cost for Expandable Products shipping:(8 x 52 = cost)                                          0
10)   Total Annual Expense for Expendable pkg. Use:(7 + 9 = Total)                                                0

      Cost of Returnable Packaging:
11)   Number of Containers Required to Fill System:
12)   Cost / Container (include dunnage if applicable):
13)   Total Container Cost(including dunnage): (11 + 12 = total)                                                  0
14)   Number of pallets Required for System:
15)   Cost / Pallet(include top cap if applicable):
16)   Total Pallet Cost: ( 14 x 15 = total)                                                                       0
17)   Total Returnable Packaging Costs: (13 + 16 = Total)                                                         0
18)   Transportation Cost for Product Shipments / Week:
19)   Total Trans. Cost for Returnable Products Shipping: (18 x 52 = cost)                                        0
20)   Trans. Cost for Product Returns / Week:
21)   Total Trans. Cost for Returnable Products Returns: (20 x 52 = cost)                                         0
22)   Total Annual Returnable Packaging / Trans. Cost: (17+19+21=total)                                           0

      COMPARISON : EXPANDABLE VS RETURNABLE PACKAGING

       Accelerated Cost      Capital Investments Annual expandable        Returnable      Returnable container
       Recovery System       for returnable cont.    Expense              Container          Total Savings
           (ACRS)                                                          Expense          (Before Taxes)
           3 Years                                      (A)                  (B)                  (C)

         year 1 ….25%                     $0.00                 $0.00             $0.00                      $0.00
         year 2 ….38%                                           $0.00             $0.00                      $0.00
         year 3 ….37%                                           $0.00             $0.00                      $0.00

      Totals                              $0.00                 $0.00             $0.00                      $0.00

      RETURN ON INVESTMENT:                                             PAYBACK PERIOD

      Three year savings, returnable vs expandable                      (Total of 22 / total of 10)*12 = months

                      0.00                  0.00                 0.00                              #DIV/0!
             Total               Returnable            R.O.I.
          Expandable              Container
           Expense                Expense
                                (3 year cost)




                                                                                                   REV 11/23/2011
                                      PACKAGING SKETCH FORM
                                              PART NUMBER:_________________________________
                                              PART NAME:____________________________________
SUPPLIER:____________________________________ DATE ISSUED:__________________________________
PACKAGING CONTACT:________________________ REVISION NUMBER:_____________________________
SIGNATURE:__________________________________ MODEL & TYPE:_________________________________
CONTACT PHONE:_____________________________ FINAL APPROVAL DATE: _________________________
1. Part Drawing or Photograph                 2. Dunnage Drawing or Photograph




Part weight: ______________________________                  # of pcs of dunnage per container: ___________
Part dimensions: __________________________                  circle one: returnable/expendable dunnage
3. Container Drawing or Photo                                4. Overall Pack Drawing or Photo




                                                             # of Containers per Pallet: __________________
Type of Container: _________________________                 Pallet Type: Returnable or Expendable
Quantity of Parts per Container: ______________              Pallet Dimensions: ________________________
Loaded Gross Weight: _____________________                   Gross Weight: ___________________________
Container Dimension: ______________________                  Overall Pack Dimensions: __________________
NOTE: Complete all sections that apply. Due to the high importance of acceptable packaging, final package acceptance
will not be given prior to one month after full production start-up. Only approvals received in writing from Delco Remy are
considered valid.
REMY APPROVALS
Technical Manager:                                           Production Control:
Continuous Improvement Engr:                                 Quality Engr:




                                                                                                          REV 11/23/2011
                                                               SKETCH FORM PART PACKAGE AND
                                                                 TRANSPORTATION DETAIL
Ship to Location:                                                                    Ship From Location:

ADDITIONAL PART DATA
Preservatives:(desiccants, oil coatings, layers, etc)

PACKAGING DATA                                   Bulk      Small Lot (circle one)
Returnable Container Type:                                          Expendable Container Type: Carton / Pallet Box / Other:
Internal Dunnage:                                                   Material: 1 Wall 2 Wall 3 Wall Other:
Outside Dimensions: (in / cm) L             W         H             Outside Dimensions:L         W           H
Pallet Dimensions (in / cm / m) L           W         H             Pallet Dimensions: L        W        H
Loaded w eight Parts + Container (LB / kg):                         Loaded Weight (LB Part + Container)
Qty/Container:           Qty/Pallet:         Pallet w eight:        Qty/Container:             Qty/pallet:
Double stackable: yes / no                                          Double stackable: yes / no

COMMENTS:




Container Ow nership:DR                %        Supplier          %                  Special Instructions:
Amortization: # of years:                  # of parts/year:           Is packaging included in pcs. price: Yes / No (circle one)

PACKAGING COST DATA                                 CURRENT              NEW         NEW
                                                    (cost/part)       (cost/part) Cost per (1) item
Carton                                                                               Carton:
Interior Dunnage                                                                     Set of Dunnage:
Pallet                                                                               Pallet:
Stretch Wrap / Banding / Belts (circle)                                              Stretch Wrap / Banding / Seat Belts:
Labels (material only)                                                               (1) Container label:
Other (please specify)                                                               (1) Ship label:
Other (please specify)
Total packaging cost for one part ($)                                                Cost Difference: $
Cost information completed by(Name & Phone #):


Transportation Data
Carrier Name:
Shipping Frequency: Day         Week       Month    Other________     Miles Traveled per trip: One Way / Round Trip

DR APPROVALS
Tech Manager:                                                       Production Control:
CI Engr:                                                            Quality Engr:
DR Packaging and Logistics:                                           Approval Date:                    Effective Date:
Return To: Delco Remy, Attn. Purchasing, 2902 Enterprise, Drive, Anderson IN. 46013
Questions: Contact Commodity Manager
                                                                                                                 REV 11/23/2011
                         TEST PACK
  DO NOT USE PARTS FOR PRODUCTION PRIOR
            TO AUTHORIZATION!

    MATERIALS MANAGER:
                PHONE:

 NOTIFY MATERIAL CONTROL UPON ARRIVAL

  Supplier:                            Contact:
     Part #:                            Phone:
 Ship Date:


TEST PACK ROUTING THROUGH FACILITY - OK
Arrived Good Condition              Part Presentation for Op
Placed to Market                    Operator Remove Empty
Timed Delivery Load
Delivery to Rack
Plant Approvals                    Name                             Date
Materials:
Quality:
Operations:
Operations Support:
Comments:




Route completed form to Commodity Manager:_______________________
Initial:______    Date:____________


                                                               REV 11/23/2011
REMY INC                                                  PACKAGING CONTAINERIZATION



Interim – Special Case Re-Packaging
Re-Packaging is required occasionally as an interim solution to a packaging change. Re-
packaging is a „quick fix” to a requirement, but can be expensive. It is strongly recommended
that strict controls be placed on re-packaging operations. In the event re-packaging is
required; a start and end date that is monitored by a closed loop system is suggested.

The following is an example of a Re-Packaging Request form. This system requires the
facility or operation in question, first gain the appropriate approvals, then implement the re-
pack. This allows the interim operation to enter the process and be appropriately monitored.




For Reference Only                        PC – 49                            REV 11/23/2011
                        RE-PACKING
                       REQUEST FORM

NAME:                                          DATE:
FOR PLANT:
SUPPLIER‟S NAME:
BUYER OF THIS PART:
PART NO:
PART NAME:
WEEKLY USAGE:
SPECIAL INSTRUCTIONS:




PLANT M.C. MGR.‟S APPROVAL:                    DATE:
PLANT Q.C. MGR.‟S APPROVAL:                    DATE:


TYPE OF CONTAINER:
PACK PER CONTAINER:
CONTAINERS PER SKID:
WHO WILL RE-PACK?        SUPPLIER    or   Other.   (circle one)



                         FAX FORM TO:
                      PACKAGING ENGINEER
                         (765) 221-6153
BUYER‟S APPROVAL:                              DATE:
PACKAGING ENGR. APPROVAL:                      DATE:

BEGIN DATE:__________________       END DATE: ______________

                                                              REV 11/23/2011

								
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