Docstoc

BULK PACKAGING HANDLING AND STORAGE INSTRUCTION FOR

Document Sample
BULK PACKAGING HANDLING AND STORAGE INSTRUCTION FOR Powered By Docstoc
					       BULK PACKAGING HANDLING AND STORAGE
      INSTRUCTION FOR CRYSTALLINE SPV MODULE




                                                                                  CNPV Dongying Solar Power
                                REVISIONS                                         Company Limited
REV   ECO/ NPA        DESCRIPTION OF CHANGE           CHK’D/DATE    APP’D/DATE    TITLE:

                                                      Yang Xiaowu     Chaudary
 A    2009-11    Release to DCC/Production                                        BULK PACKAGING HANDLING
                                                      Nov18,2008     Nov18,2008
                                                                                  AND STORAGE INSTRUCTION
                                                      Yang Xiaowu    Chaudary     FOR CRYSTALLINE SPV MODULE
 B    2010-09    Company Name Change
                                                       Sep4,2010     Sep4,2010

                                                      Yang Xiaowu    Chaudary     SPECIFICATION NO:    PART NO:
C     2011-03    Added New Modules Types
                                                       Mar1,2011     Mar1,2011    CNPV-PS-M-S0006           N/A
                 Added New Eco-Friendly package for   Yang Xiaowu    Chaudary               DRAWN BY          REV:
D     2011-10
                 60/54-156mm Modules                   Oct1,2011     Oct1,2011              Chaudary              D

                                                                                    SHEET        1     OF         1
                                                                TECHINICAL SPECIFICATION

   TITLE:                                                    SPEC. NO.:                         CNPV-PS-M-S0006

   BULK PACKAGING HANDLING & STORAGE
   INSTRUCTION FOR CRYSTALLINE SOLAR                         REVISION:                          D
   PHOTOVOLTAIC MODULE
                                                             EFFECTIVE DATE:                    Oct. 2011

   AUTHOR(S):                Bypina Veerraju Chaudary, Yang XiaoWu                                  Page 1 of 13


    Many of our customers have encouraged us in the past to redesign the packing of our modules.
    Traditionally couple of module comes in its own cardboard box and 19 boxes are then placed on a pallet
    and packed in a stretch wrapping. The disadvantage is that all this material has to be recycled as it
    doesn’t make sense to return it to our factories.

    The new bulk packaging has been developed under a joint effort involving Module Technology, Production,
    Supply Chain, Quality, Sales, Warehouse and Suppliers as well as External Testing Agencies and many
    others. This new design can be used for all 54, 60 and 72 cells modules produced by CNPV. Detailed
    information is shown in table-1.

    Table-1 Specification of bulk package for 54/60/72-cell module
                 Solar PV Module                                                 Bulk Package

                                                      Module
                                        Dimension       Q’ty    Dimensions        Gross      Module Q’ty per         Max.
  Config.          Type(Typical)         L×W×H          Per       of Pallet       Weight       container           Stacking
                                          (mm)         pallet   L×W×H (mm)         (kg)          (pcs)             Number
                                                       (pcs)

72-125M/B     CNPV-160M to 210M         1581×809×40     24      1690×1145×1000      400    24x28pallet=672(40ft)      3

              CNPV-190M-54 to 240M-54                                                      24x28pallet=672
54-156M/P/B                             1482×992×40     24      1590×1145×1190      490                               2
              CNPV-190P-54 to 235M-54                                                      (40ft, High Cubic)
              CNPV-220M to 265M                                                            24x26pallet=624
60-156M/P/B                             1650×992×40     24      1758×1145×1190      510                               2
              CNPV-210P to 260P                                                            (40ft, High Cubic)
              CNPV-255M to 320M                                                            21x22pallet=462
72-156M/P/B                             1965×992×46     21      2073×1135×1190      570                               2
              CNPV-250P to 315P                                                            (40ft, High Cubic)


    Main requirements that have been taking into account were:
                Safety: manufacturing, handling and manipulation, waste and environment.
                Customer needs, including feedback on real samples
                Efficiency and cost benefits

    The new packing is designed for maximizing modules per container. As opposed to the horizontal stacking
    of modules that was done before, the modules are now placed vertically.




                    A great example of improvements from Module Technology in packaging efficiencies
                                                             TECHINICAL SPECIFICATION

TITLE:                                                 SPEC. NO.:                          CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR                      REVISION:                           D
PHOTOVOLTAIC MODULE
                                                       EFFECTIVE DATE:                     Oct. 2011

AUTHOR(S):             Bypina Veerraju Chaudary, Yang XiaoWu                                   Page 2 of 13


The new packing has the following many many advantages:
          Significant reduction of waste. Reduction of the amount of cardboard to recycle!
          Easier to recycle by elimination of the paper and play wood in the pallet
          Reduces cost of entire packaging & transportation value chain which in turn requires less
          energy demand across the supply chain
          Increase container capacity use
          Reduce the number of manipulations.
          Testing according to the most demanding test from ISTA passed successfully
          Improved protection compared to the current packing method-based on a comparative test
          Ultimately leading to Customers Happy

In summary we are confident that this improvement will save you on all above areas and that you and
your customers will soon appreciate the benefits of this latest product improvement from CNPV.

                                               *********
The following are recommendations for the proper packing, unpacking, storing and moving of the New
Bulk Pack Carton for standard modules at CNPV facilities.

The PV modules are packaged in a box made from triple-strength cardboard and resting on a wooden
pallet. The outer carton tube lid of the box is made from double strength cardboard

Handling Instructions: Preparing to pack the bulk pack carton solution: CNPV Factory & potentially Distributors
• Includes all standard modules accept those packaged for Europe, North America & Asian customers.
• Prepare bulk pack solution next to/at end of the finished module table/conveyor line for module
   insertion.
• Unfold and form outer box carton tube for bulk modules as per Figure # 1 & 2 below and place
   centered on pallet next to finished module table/conveyor line.




              (Figure# 1&2 Wooden pallet made with Pine wood and HT processed as per ISPM15)
                                                             TECHINICAL SPECIFICATION

TITLE:                                                  SPEC. NO.:                       CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR                       REVISION:                        D
PHOTOVOLTAIC MODULE
                                                        EFFECTIVE DATE:                  Oct. 2011

AUTHOR(S):                Bypina Veerraju Chaudary, Yang XiaoWu                              Page 3 of 13


♦       Inside the box, 21 or 24 modules are placed vertically in specified separator location. Each module is
        protected with vertical separator on each side within the box as can be seen in Figure#3&4

•       Important note: The first & last module placed in the carton should be placed so that the module
        glass faces the outer carton wall.




                                     Figure# 3 Front view & Figure# 4 Side view

    •     Inside the box each module is placed in specified location of the vertical separators strips (see
          Figure# 5 & 6). As shown throughout and in Figure#4 below, CNPV recommends that two people
          should load into and remove the modules from the new bulk pack carton for solar PV modules as
          follows…

    •     With one hand in the middle of each short side of the frame / divider and the other hand grasping
          the frame near the corner divider on the top and long side, place the module in the bulk carton
          standing vertically with the long sides of the frame on the top and bottom. There is a symbol on the
          outer carton depicting two people handling the modules as described in carton decorations section
          later.

    •     Note: One person should not attempt to pick up the module by the long side of the frame as this
          may cause frame integrity damage. It could also lead to back strains.
                                                         TECHINICAL SPECIFICATION

TITLE:                                              SPEC. NO.:                        CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR                   REVISION:                         D
PHOTOVOLTAIC MODULE
                                                    EFFECTIVE DATE:                   Oct. 2011

AUTHOR(S):            Bypina Veerraju Chaudary, Yang XiaoWu                               Page 4 of 13




                       Figure#5 &6 Placement of modules into vertical separators
  •   Upon loading all modules, for additional protection, 3 pieces of horizontal separator cardboard piece
      are inserted at extreme ends and middle position of the box to avoid any free space and potential
      movement inside the box during transit (see Figure# 7, 8 & 9)

      Note: for 156*156-cell module, two additional small vertical separators need to be put into both
      sides module.
                                                         TECHINICAL SPECIFICATION

TITLE:                                             SPEC. NO.:                        CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR                  REVISION:                         D
PHOTOVOLTAIC MODULE
                                                   EFFECTIVE DATE:                   Oct. 2011

AUTHOR(S):            Bypina Veerraju Chaudary, Yang XiaoWu                                 Page 5 of 13




                  Figure# 7, 8 & 9- pieces of Horizontal Separator cardboard Protection
  •   Then construct the carton top cap and install on bulk carton. See the Figure# 10&11
                                                            TECHINICAL SPECIFICATION

TITLE:                                                SPEC. NO.:                         CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR                     REVISION:                          D
PHOTOVOLTAIC MODULE
                                                      EFFECTIVE DATE:                    Oct. 2011

AUTHOR(S):             Bypina Veerraju Chaudary, Yang XiaoWu                                  Page 6 of 13




         Photos 10 &11- 3 pieces of Horizontal Separator cardboard Protection & Top Lid closing
•   Utilize plastic strapping to secure the top lid cap and the corrugated carton tube to the pallet, strapping
    across both length and width as per picture below. Make use of small plastic/corrugated braces under
    the strapping. Figure #14 shows the fully packaged with the top cap and strapping.




               Figure12, 13 & 14-strapping, plastic protector and the show of fully package
                                                                TECHINICAL SPECIFICATION

TITLE:                                                     SPEC. NO.:                         CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR                          REVISION:                          D
PHOTOVOLTAIC MODULE
                                                           EFFECTIVE DATE:                    Oct. 2011

AUTHOR(S):                 Bypina Veerraju Chaudary, Yang XiaoWu                                  Page 7 of 13


Basic Safety Rules
Handling
•       Move full bulk pack solution via forklift or jack entering from the short side.
•       Warning: For safety reasons never manipulate or move a partially full carton, without stabilizing the
        remaining modules against shifting. Movement may cause the remaining modules in a partially full
        carton to shift within the carton, even with the stabilizing horizontal separator strips affixed, causing an
        unsafe handling situation, particularly when utilizing a forklift.


NOTE: The photographs have been taken of a prototype box. In the final product the barcode will be stuck
to the outside of the cardboard box.

    •     When handling goods it is obligatory to use correct safety equipment: eg: gloves
          and safety shoes.
    •     Move closer to the object when lifting.
    •     Make sure you have a strong foothold, keeping feet evenly spaced.
    •     Two people are necessary to lift modules, one person on each short side.
    •     Do not lift a heavy weight above the waist in a single movement.
    •     When lifting a module above waist height you should not have your arms fully
          extended, always with your arms bent.
    •     Check beforehand the route you will take when moving the goods, making sure
          there are no obstacles in the way.
    •     Anything that may cause physical injury due to excess weight should be moved by
          mechanical means (eg: forklift etc...)
    •     Keep the work area clean.
                                                  TECHINICAL SPECIFICATION

TITLE:                                       SPEC. NO.:                   CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR            REVISION:                    D
PHOTOVOLTAIC MODULE
                                             EFFECTIVE DATE:              Oct. 2011

AUTHOR(S):          Bypina Veerraju Chaudary, Yang XiaoWu                     Page 8 of 13


             Container Loading & Handling Guide Lines & Instructions:
  •   The boxes should always be handling using mechanical equipment (eg. Forklift
      truck).
  •   The pallets are apt for fork lift usage from each of the 4 sides.
  •   Pallets should be stored a maximum of 2 high in the container.
  •   It is recommended that loading is done lengthwise both in trucks and containers;
      this also applies to storage in warehouses.
  •   For lengthwise handling is it necessary to attach extensions to the forks of the
      truck, to reach at least 1,5m length.




  •   Pallets should be piled one on top of the other so that corners are flush and there is
      no overhang. The critical path for the loading of the new 23in1 bulk is to align the
      pallets in the container with equal gaps as shown in the picture below for the 1st
      tier and also align the second tier exactly on the 1st tier in order to prevent the
      overhang or damage of the pallets.
                                                TECHINICAL SPECIFICATION

TITLE:                                      SPEC. NO.:               CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR           REVISION:                D
PHOTOVOLTAIC MODULE
                                            EFFECTIVE DATE:          Oct. 2011

AUTHOR(S):         Bypina Veerraju Chaudary, Yang XiaoWu                 Page 9 of 13




  •   Once loaded the goods should be attached inside the storage area of the truck or
      container, so as to avoid any kind of movement. All trucks or containers must be
      provided with straps to fasten the goods
  •   Once loaded the goods are locked with supporting wooden planks nailing on the
      floor board to prevent shifting.
  •   The container doors should be locked properly, so as to avoid any kind of
      movement.
                                                  TECHINICAL SPECIFICATION

TITLE:                                        SPEC. NO.:                  CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR             REVISION:                   D
PHOTOVOLTAIC MODULE
                                              EFFECTIVE DATE:             Oct. 2011

AUTHOR(S):          Bypina Veerraju Chaudary, Yang XiaoWu                     Page 10 of 13


Analysis of risks and preventative measures
  TASK                 RISKS                     PREVENTATIVE MEASURES
               Falling objects during     - Use of safety shoes
               handling                   - Avoid distraction
               Hitting standing/moving    - Avoid distraction
               objects                    - Neat and tidy work area
               Cuts                       - Use of safety gloves
                                          - All cutters or other type of bladed implement
                                          should be a safety version
 Manual        Overexertion and back      - Training and information to workforce regarding
Handling of    injuries                   the correct way to handle loads and the potential
 Modules                                  risks (according to the laws of the country in
                                          question)
                                          - Whenever possible use mechanical lifters
               Tripping                   - Avoid distraction
                                          - Use of safety shoes
                                          - Neat and tidy work area
               Physical tiredness         - Take rest as necessary according to risk
                                          evaluation
               Accidents involving        - Signposting the loading area and warehouse as
               vehicles                   required by law of the country in question.
                                          - Only use the lanes signaled and set aside for
                                          vehicle movement, ensuring that visual and audio
                                          warnings are clear.
                                          - Regular servicing of vehicles (as necessary in
 Mechanical                                   EU,NA & MOW and according to the law of
 Handling of                                  the country in question)
  Modules                                 - Employees should receive necessary training
(forklift truck                           before using such equipment.
and loading
                Objects falling through   - Keep surfaces in good repair, avoiding slippery
    bays)
                collapsing or slippage    areas or non-uniformity
                                          - Respect maximum loads for all equipment
               Pallets falling during     - As the measurements of the pallets are above
               handling                   Standard size, it is recommended that extensions
                                          are used to help stability. (at least 1,5m long)
                                                  TECHINICAL SPECIFICATION

TITLE:                                       SPEC. NO.:                   CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR            REVISION:                    D
PHOTOVOLTAIC MODULE
                                             EFFECTIVE DATE:              Oct. 2011

AUTHOR(S):          Bypina Veerraju Chaudary, Yang XiaoWu                     Page 11 of 13


Inspection of external packaging after receiving the goods
To ensure that the products inside are not damaged it is first necessary to make a visual
check:

  •   The pallet should be in good condition: that is to say without broken or badly
      fastened slats or other elements.
  •   Ensure that the box and lid are in perfect condition; i.e.: there is no evidence of it
      having been hit or dented, no breakage or other visual defects.
  •   Ensure that the boxes are correctly aligned to the pallet dimensions.


Removal of Modules from the bulk pack box
  •   Remove the plastic strip using the correct cutting device (see Figure#15 )




                                         Figure#15
  •   Lift the box lid (see Figure#16)




                                         Figure#16
                                                TECHINICAL SPECIFICATION

TITLE:                                      SPEC. NO.:                  CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR           REVISION:                   D
PHOTOVOLTAIC MODULE
                                            EFFECTIVE DATE:             Oct. 2011

AUTHOR(S):         Bypina Veerraju Chaudary, Yang XiaoWu                    Page 12 of 13


Suggestion: The box lid, once on the floor could be used as a base for resting the
modules as they are removed, thus protecting them from potential damage.
 • Take out the horizontal separator strips (see Figure#17 )




                                        Figure# 17
  •   The modules should be removed from vertical separators strips one by one by 2
      people by grasping the short sides (see Figure#18 )




                                        Figure# 18
  •   Place the module in a safe place to avoid damage. The box lid is a good option.
  •   Repeat the process with all modules until all are out of the box.
  •   Removal and handling of modules should always be undertaken by 2 people and
      the line of vision should never be impaired. During handling or movement of
      modules take care never to take up a potentially dangerous posture. When moving
      more than one module you should always use mechanical equipment.
  •   Never lift the module alone, grasping the middle section. Modules should always be
      handled by 2 people, using the short sides.
                                                  TECHINICAL SPECIFICATION

TITLE:                                       SPEC. NO.:                   CNPV-PS-M-S0006

BULK PACKAGING HANDLING & STORAGE
INSTRUCTION FOR CRYSTALLINE SOLAR            REVISION:                    D
PHOTOVOLTAIC MODULE
                                             EFFECTIVE DATE:              Oct. 2011

AUTHOR(S):          Bypina Veerraju Chaudary, Yang XiaoWu                     Page 13 of 13


Storage
  •   Pallets should be handled so as to minimize any chance of damage to the box or
      its contents.
  •   Any transportation within the warehouse should be authorized by the correct
      person.
  •   All handling inside or outside the warehouse using a machine should only be
      undertaken by people correctly trained for this activity.
  •   Pallets should be handled using forklift trucks or loading bays.
  •   For safety reasons pallets should not be piled more than specified layers as shown
      on the outer carton box tube , and they should only be moved using the correct
      mechanical equipment.
  •   Pallets should be piled one on top of the other so that corners are flush and there is
      no overhang.
  •   The warehouse should be correctly laid out and the storage area clearly signaled.




                                          *********

				
DOCUMENT INFO
Shared By:
Categories:
Tags:
Stats:
views:3
posted:10/16/2012
language:Unknown
pages:14