Global E Export Ma arket Pack kagin ng Terrms a and C Cond dition ns
IM C
IM C
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120
IM C
130
ISO-M Modular Carton n (IMC) Gllobal 175 50 Exportt Packag ging Term ms & Con nditions
Ma aterial Planning & Logistics Ju uly 2013
Ford Motor Company – Global Export Market Packaging Terms and Conditions
Contents PAGE 1.
INTRODUCTION ..........................................................................................
3
2.
BACKGROUND ...........................................................................................
4
3.
HOW TO USE THIS DOCUMENT ................................................................
5
4.
DO's .............................................................................................................
6
5.
DO NOT ........................................................................................................
7
6.
IMC EXPORT CARTON SELECTION PROCESS .......................................
8
6.1.
NORTH & SOUTH AMERICA FORD ISO-MODULAR CARTON SIZES AND PERFORMANCE SPECIFICATION .....................................
9
TABLE 1: FORD ISO-MODULAR CARTON SIZES (NORTH AND SOUTH AMERICA) ..................................................................................
10
EUROPE AND ASIA PACIFIC FORD ISO-MODULAR CARTON SIZES AND PERFORMANCE SPECIFICATION .....................................
12
TABLE 2: FORD ISO-MODULAR CARTON SIZES (EUROPE AND ASIA PACIFIC) .........................................................................................
13
UNIT LOAD CONSOLIDATION AND SHIPPING GUIDELINES ..................
16
6.2. 6.3. 6.4. 7.
7.1.
GUIDE TO LOAD CARTONS ONTO PALLET BASE ...............................
17
8.
ISO-MODULAR PALLET SPECIFICATION.................................................
19
9.
PHYTOSANITARY AND PACKAGING MATERIAL SELECTION ...............
20
10. CORROSION PREVENTION OVERVIEW ...................................................
21
11. FINAL EXPORT PACKAGING CHECKLIST ...............................................
22
Attachment "A": Export Market Packaging FAQs ..........................................
24
Attachment "B": Contacts ................................................................................
30
Attachment "C": Recommended Packaging Suppliers .................................
35
List of revisions Date
Description of change
01/04/2009
Initial Release
29/03/2010
New Release July 2011
30.03.2012
Update Release July 2012
30.03.2013
Update Release July 2013
EXPORT 1750-Global
July 2013
Changed by J.Ader; M.Krings; C.Krishnamachari J.Ader; M.Krings; R.Suresh Kumar J.Ader; M.Krings R.Ramkumar J.Ader; M.Krings R.Ramkumar
Sections affected All All CMMS input; shipping labelling CMMS input; shipping labelling
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
1. Introduction This guide is to advise Ford suppliers of the packaging requirements for the shipment of components to EXPORT markets. If you are unsure as to which territories are deemed as export for your company; please contact your Ford buyer, Supply Chain Management contact or MP&L Export Packaging Engineering contact. These guidelines do not apply where the suppliers provide the freight from the place of origin to an overseas regional supplier operated warehouse. This is when Ford purchasing has sourced material as 'Ex local warehouse' or 'FOB supplier's local distribution center'. In these cases suppliers must refer to regional local packaging terms and conditions, e.g. the MFG1750 or the EU1750 to define part packaging. These guidelines aim to standardize packaging methods for all Ford export markets, to ensure quality is maintained, freight cube is maximized, and to be acceptable and adaptable to local market conditions. This Global Export packaging Terms & Conditions document supersedes all previous regional export packaging guidelines and is – from now on – the single document for all export market packaging of Ford Motor Company. In case that local conditions have to be considered this is specifically described within the document as a local deviation. Use this specification for all parts that do not yet conform to the Ford IMC packaging standard. Existing approved IMC packaging must be in compliance with the latest guidelines. From these guidelines it is expected that the supplier will develop an export packaging specification and submit it to the contacts detailed below for provisional or final approval. If you supply components in packaging that does not conform to the specification you may be held liable for repackaging and incremental freight costs. Deviations are not allowed without prior written approval from Packaging Engineering. Packaging that proves unacceptable for whatever reason (quality, transport, production process, safety, etc.) must be changed upon request from Packaging Engineering. Remember, the responsibility for ensuring component quality from your plant to the point of use remains with you - the supplier of the product. When your proposal is ready, complete the Export Packaging Data-Set. Refer to the table below to determine the how to submit your packaging proposal. Destination Market
Form to be used
Transition path to GPP
The Americas
GPP
Fully rolled out
Eu1121E & GPP
In 2013 GPP is piloted for selected programs. Communication incl. timing and detailed instructions to affected suppliers will be provided via e-mail.
APA1121 & GPP
GPP roll out in 2013 for selected programs. Communication incl. timing and detailed instructions to affected suppliers will be provided via e-mail.
Europe
Asia Pacific & Africa
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
Note: Ford Motor Company is transitioning starting 2013 to a new Packaging Data Management System for packaging approval. The Global Packaging Portal has already replaced the current Form 150, 150E processes for input to the Americas and will replace the EU1121, EU1121E, and APA 1121 procedures/forms in future. Detailed information is provided through the GPP roll out project. Any supplier who is requested to provide the packaging proposal through GPP instead of e-mailing it to the packaging engineer will receive clear instructions through roll out mails. Packaging data communication through GPP is web based. For the carry over packaging data communication, EU1121 EU1121E and APA1121, it is required that your proposal is completed via e-mail. The GPP website location is: www.packaging.ford.com To obtain an electronic version of this Guideline document or an electronic packaging specification Form go to Covisint https://portal.covisint.com, CLICK THROUGH THE FOLLOWING LINKS: .. Partner Portals -- Ford Supplier Portal .. Important Documents -- Global Terms & Conditions .. Production .. GTC Web-Guides Global Export Market Packaging Terms and Conditions Export Packaging Form EU1121e / APA1121
2. Background The Ford ISO-Modular Carton (IMC) program is a corrugated box footprint strategy designed to "module" standard ISO-Sea Containers. Using modular footprints allows unit load cubing at Ford consolidation centers and direct material loading into ISO-Sea Containers. This strategy is required to maximize freight and quality while eliminating non-value added handling and crating. Packaging is based around a unit load footprint size of 980mm x 1140mm x 1100mm (39" x 45" x 43") and NOT the standard shipping pallet dimensions of 1200 x 1140 (48" x 45") or any other specification . Due to the introduction of lean manufacturing techniques into all Ford plants, all packaging quantities and sizes are required to allow for manually handable cartons wherever possible – i.e. manually handable cartons should, ideally, weigh less than 15kg (33 lbs). To assist suppliers in selecting the correct packaging size, Ford has developed IMC Export Packaging Selection Guidelines supporting the development of an ideal packaging solution for any export part.
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
3. How to use this Document To ensure that all export packaging is in accordance with Ford requirements follow these steps: Step 1:
For each export which is shipped to export markets, select the ideal expendable corrugated IMC solution using the given requirements and Export Packaging Selection Guidelines (Chapter 6).
Step 2:
Advise Packaging Engineering of your packaging proposal by completing the GPP input or a copy of the EU1121e or APA1121 forms.
Step 3:
If internal dunnage is required or special part protection included in your Packaging Proposal Input.
Step 4:
Packaging Engineering will review the proposal and then provide approval or rejection through the Global Packaging Portal or e-mail communication (EU1121e or APA1121).
Step 5:
Suppliers must ensure that all export shipments are made in accordance to the Shipping & Consolidation Guidelines to achieve optimized cube utilization in transportation (Chapter 7).
Step 6:
Complete final checklist to ensure that all steps have been covered (Chapter 11) At any given point of time Packaging Engineering can approach the supplier to revise the packaging specification when needed (i.e. change in mode of transportation). Packaging costs must be identified and integrated as part of your piece price at the quotation stage, and can only be agreed by Purchase (your commodity buyer). Confirmation of a packaging specification form advises that your packaging proposals are acceptable, and does not infer or imply acceptance or agreement of any associated costs with that packaging.
Before entering into Step 1 (Selecting the correct export carton) please consider the following guidelines:
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
4. Do's
DO ensure that you use modular cartons and pallets to the exact specification - this is a fully integrated system that requires each element to meet its specification.
DO ensure that you utilize the maximum cube of the carton - if utilization is less than 95% try another IMC size or part orientation.
DO where rusting is a risk ,use corrosion inhibiting materials; i.e. VCI products, etc. For other components, where required, use the appropriate product quality enhancement material; i.e. bubble wrap, static-proof bags, etc. Although Packaging Engineering will advise, the responsibility for ensuring part protection remains with the supplier.
DO select reliable suppliers to provide cartons, pallets, and stickers. Ford has approved companies that currently stock IMC boxes if you do not have a company to provide the proper materials. Please contact Export Packaging Engineering to obtain contact information.
DO monitor the effect of engineering changes on the packaging and submit a new formal packaging proposal through GPP/EU1121E or APA1121 whenever the packaging changes
DO inform Packaging Engineering using appropriate pack spec. form if your parts are temperature sensitive. (Temperatures over 70 C can be reached during transport to some destinations).
DO ensure your part labeling conforms to Ford Shipping Parts/Identification Label Standard BAO-1122-L. The BAO-1122-L document is available through the FSP (Ford Supplier Portal).
DO follow all applicable Hazardous Materials / Dangerous Goods Transportation Regulations, including the OSHA and UN Hazard Communication Standards. Refer to the EU1750 Packaging Terms & Conditions or the N.A. Packaging Guidelines for more details. Adherence to transport regulations of hazardous material / dangerous goods is legally mandated. Regional and / or national requirements must be followed.
DO use new part labels when shipping parts with new engineering level. Refer to the regional packaging terms & condition documents for label details.
DO ensure quantities of handles/hand holes is suitable for the pack weight (See specification)
DO ensure that weight identification discs are fitted next to the IMC Number printing and are clearly visible. Required disc size is approximately 50mm (2") in diameter. Discs may be stickers or similar markings i.e. stamp, marker etc.
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
DO ensure that all cartons have the appropriate ISO-Modular Carton Number printed approximately 50mm (2") high on two sides of the box. See Example:
IMC100 (ISO-Modular Carton Number) (Weight Identification Disc)
5. DO NOT
Do not use a carton that is not specified in Table 1 for NA & Table 2 for EU & APA - no exceptions are permitted without prior written approval from Packaging Engineering.
Do not forget to include the required IMC Number printing on two sides of the box and do not ship on a Non-IMC pallet.
Do not design an open top IMC proposal. No open top containers are allowed.
Do not allow your product quality to be compromised due to inadequate packaging zero defect is the norm. If weight is an issue, suppliers are required to increase the packaging strength requirements to ensure quality.
Do not pack different parts within the same carton - only one part number per carton is allowed. Different part numbers, in separate IMC boxes, shipped on the same pallet must be accompanied by a master packing label.
Do not use belly bands to strengthen IMC cartons. Excessively heavy unit loads require the use of increased board strength, dunnage, or corner posts to ensure quality.
Do not use steel banding to secure loads - use plastic banding and/or stretch wrapping.
Do not allow cartons to overhang pallets. Ensure they are correctly stacked and positioned. The appropriate use of banding and/or stretch wrap must be used as needed.
Do not use staples for carton closure (top or bottom). Staples may damage both the parts and the operators during the unload operation.
Do not ship pyramid loads whenever possible to prevent inbound transit damage.
Do not use packaging material that cannot be re-cycled, or could be environmentally harmful after disposal.
Do not cut down or modify modular boxes. Example: do not cut side seams to make a box smaller or insert an access panel unless approved by Ford Packaging Engineering.
Do not allow the maximum weight of a unit load including pallet base to exceed the specified weight limit for the region (see sections 6.1 and 6.3 for weight limits).
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
6. IMC Export Carton Selection Process Identify the most suitable carton from the Ford IMC container ranges (refer Table 1 in section 6.2 or table 2 in section 6.4) based on the following selection criteria: 1. Determine an approximate pack quantity based on part nature, FPS right sizing principles, plant material handling requirement, line feed requirement data (if available) and optimum part density in carton. 2. Determine whether the part requires any special expendable/durable packaging. If required contact respective regional packaging engineer before finalizing your packaging proposals. 3. Apply color weight disc to outside of all cartons , remember to also select the appropriate quantity of hand holes based upon: Carton Weight ** Up to 12kg (26lbs) Up to 30kg (66lbs) Up to 60kg (132lbs) Specials and above 60kg
Weight Disc Red discs Yellow discs Green discs Blue discs
O O O O
Handles No handles 2 handles 4 handles On Pallet Base
** Note: MH&PE engineer to contact supplier when a deviation is required.
4. All standard IMC shipments must be shipped on the specified IMC Export Block Pallet 980mm x 1140mm (39" x 45") as shown in section 8. In case that the IMC carton size exceeds the dimensions of the standard pallet then a special pallet with same foot print size of the carton used is required .This special pallet must follow the same construction principle as the standard pallet and must be suitable for the increased weight and handling requirements. 5. Finally, all IMC unit loads must be adequately secured to the pallet. Manually handable cartons (IMC010-IMC180) should be secured to the pallet base with a minimum of four bands and/or the appropriate amount of stretch wrap. If stretch wrap is used, be sure to make several rotations around the pallet base to prevent carton movement in transit. Stapling unit load sized cartons to the pallet base in certain cases is recommended to prevent movement in transit. If you want to staple the carton to base pallet then please contact the regional packaging engineer before doing so. 6. If your parts are to be shipped by air freight directly from your manufacturing location, cartons must be placed in a wood or corrugate over pack. This requirement is to adequately protect it from air freight handling and in-transit forces. It is mandatory to maintain a minimum of 12mm thick wood overpack if it is plywood and 15mm in case of Pine wood. However, wood used must comply with the phytosanitary requirements in section 9 of this document.
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
6.1 North & South America IMC Carton Sizes and Performance Specifications The following applies to import and exports from the Americas and supersede Section 6.3. IMC Exterior Exterior Tare Minimum Carton Maximum Carton Dimensions (mm) Dimensions Weight Burst Flute Box Weight (in) Number (est.) Strength Size Design Per Box L W H L W H kg (lbs) (lbs) (Combo) (Type) @ Kg (lbs) IMC010 140 240 120 9.5 5.5 4.75 0.1(0.3) 275 # C RSC 15 (33) IMC020 140 240 240 9.5 5.5 9.5 0.2 (0.4) 275 # C RSC 15 (33) IMC030 280 240 120 11 9.5 4.75 0.2 (0.5) 275 # C RSC 15 (33) IMC040 280 240 240 11 9.5 9.5 0.3 (0.7) 275 # C RSC 15 (33) IMC050 280 480 120 19 11 4.75 0.4 (0.8) 275 # C RSC 15 (33) IMC060 280 480 240 19 11 9.5 0.7 (1.6) 275 # C RSC 15 (33) IMC070 560 240 120 22 9.5 4.75 0.3 (0.8) 275 # C RSC 15 (33) IMC080 560 240 240 22 9.5 9.5 0.8 (1.7) 275 # C RSC 15 (33) IMC090 560 480 120 22 19 4.75 1.3 (2.9) 275 # C RSC or FTD 15 (33) IMC100 560 480 240 22 19 9.5 2.1 (4.5) 400 # CA RSC 15 (33) IMC110 560 480 480 22 19 19 2.8 (6.1) 400 # CA RSC 15 (33) IMC120 560 960 120 38 22 4.75 2.3 (5.0) 275 # C RSC or FTD 15 (33) IMC130 560 960 240 38 22 9.5 3.9 (8.5) 500 # CA RSC 15 (33) IMC140 560 960 480 38 22 19 5.1 (11.2) 500 # CA RSC 15 (33) IMC150 1120 480 120 44 19 4.75 1.7 (3.7) 275 # C RSC or FTD 15 (33) IMC160 1120 480 240 44 19 9.5 3.7 (8.1) 500 # CA RSC 15 (33) IMC170 1120 480 480 44 19 19 4.9 (10.8) 500 # CA RSC 15 (33) IMC180 1120 960 240 44 38 9.5 8.2 (18.0) 500 # CA RSC The carton IMC190 1120 960 480 44 38 19 9.6 (21.2) 500 # CA RSC or HSC & LID weight IMC193 1120 960 480 44 38 19 12.7 (28.0) 1100 # CAA RSC or HSC & LID capacity IMC197 1120 960 600 44 38 23.6 10.2 (22.5) 500 # CA RSC or HSC & LID varies IMC200 1120 960 960 44 38 38 12.3 (27.1) 450 # CA RSC or HSC & LID depending on the pack IMC203 1120 960 960 44 38 38 17.0 (37.4) 1100 # CAA RSC or HSC & LID design. For IMC400 1300 1120 960 51 44 38 21.4 (47.2) 1100 # CAA HSC & LID the smaller IMC410 1300 1120 480 51 44 19 16.4 (36.2) 1100 # CAA HSC & LID hand held cartons the IMC420 1450 1120 960 57 44 38 17.4 (38.4) 1100 # CAA HSC & LID maximum IMC430 1450 1120 480 57 44 19 17.4 (38.4) 1100 # CAA HSC & LID weight is IMC440 1680 1120 960 66 44 38 24.8 (54.6) 1100 # CAA HSC & LID defined by IMC450 1680 1120 480 66 44 19 18.0 (41.8) 1100 # CAA HSC & LID the IMC460 1960 1120 960 77 44 38 27.0 (59.6) 1100 # CAA HSC & LID ergonomic IMC470 1960 1120 480 77 44 19 20.9 (46.0) 1100 # CAA HSC & LID weight limit IMC480 2260 960 960 89 38 38 25.9 (57.0) 1100 # CAA RSC or HSC & LID (15kg) IMC490 2260 960 480 89 38 19 19.3 (42.6) 1100 # CAA RSC or HSC & LID Tolerance: Exterior dimensions must be maintained to +0.0 and -5.0mm (+0" and -0.2").
Notes: 1. All hardware parts are to be packaged in standard IMC030 or quarter keg (229mm x 229mm x 127mm) cartons. 2. RSC = Regular Slotted Carton, HSC = Half Slotted Carton, and FTD = Full Telescope Design StyleRolled ends may be used on FTD cartons. 3. All cartons from Asia Pacific countries must have US Kraft liners and be purchased from a Ford North American International Packaging Engineering approved packaging supplier. 4. Maximum weight of a unit load including the pallet base must not exceed 600kg (1,320lbs). EXPORT 1750-Global
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
6.2 ISO-MODULAR CARTON (IMC) SIZES – North & South America Mixed unit loads of different parts and carton sizes ARE acceptable, the modular carton design allowing all cartons to be inter-stacked. Do not add empty cartons to the pallet stack to achieve a flat layer. Homogeneous unit loads are shown simply to illustrate relative carton size and orientation on the ISO-Modular pallet.
IMC010
IMC020
IMC030
IMC040
IMC050
IMC060
IMC070
IMC080
IMC090
IMC100
IMC110
IMC120
IMC130
IMC140
IMC150
IMC170
IMC180
IMC190/193
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IMC160
IMC200/203
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
IMC400
IMC410
IMC420
IMC430
IMC440
IMC450
IMC460
IMC470
IMC480
IMC490
Box Number IMC400 IMC410 IMC420 IMC430 IMC440 IMC450 IMC460 IMC470 IMC480 IMC490
Carton Outside Dimensions millimeters (inches)
Pallet Dimensions millimeters (inches)
L
W
D
LxWxD
1300 (51) 1300 (51) 1450 (57) 1450 (57) 1680 (66) 1680 (66) 1960 (77) 1960 (77) 2260 (89) 2260 (89)
1120 (44) 1120 (44) 1120 (44) 1120 (44) 1120 (44) 1120 (44) 1120 (44) 1120 (44) 960 (38) 960 (38)
960 (38) 480 (19) 960 (38) 480 (19) 960 (38) 480 (19) 960 (38) 480 (19) 960 (38) 480 (19)
1320 (52) x 1143 (45) x 127 (5) 1320 (52) x 1143 (45) x 127 (5) 1473 (58) x 1143 (45) x 127 (5) 1473 (58) x 1143 (45) x 127 (5) 1702 (67) x 1143 (45) x 127 (5) 1702 (67) x 1143 (45) x 127 (5) 1981 (78) x 1143 (45) x 127 (5) 1981 (78) x 1143 (45) x 127 (5) 991 (39) x 2286 (90) x 127 (5) 991 (39) x 2286 (90) x 127 (5)
# Not all IMC carton sizes are shown as sketches.
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
6.3 European & Asia Pacific IMC Carton Sizes and Performance Specifications The following applies to European & Asia Pacific imports -if shipping region is the Americas see 6.1 IMC Carton Number
IMC010# IMC011* IMC020# IMC030# IMC031* IMC040# IMC050# IMC060# IMC070# IMC080# IMC090 IMC100 IMC110 IMC120 IMC130 IMC133 IMC136 IMC140 IMC142 IMC144 IMC147 IMC150 IMC160 IMC170 IMC180 IMC186 IMC190 IMC193 IMC197 IMC197HC IMC200 IMC210 IMC220 IMC230 IMC240 IMC250 IMC260 IMC270 IMC280 IMC290 IMC300 IMC310
Exterior Dimensions (mm) (in) L 140 140 140 280 280 280 280 280 560 560 560 560 560 560 560 560 560 560 560 730 800 1120 1120 1120 1120 1120 1120 1120 1120 1120 1120 1240 1460 1470 1470 1470 1470 1470 1660 1740 1740 2240
W 240 240 240 240 240 240 480 480 240 240 480 480 480 960 960 960 960 960 960 560 980 480 480 480 960 960 960 960 960 960 960 480 1120 560 560 560 1120 1120 800 1120 1120 1120
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H 120 120 240 120 120 240 120 240 120 240 120 240 480 120 240 280 360 480 600 480 320 120 240 480 240 360 480 560 600 730 960 480 840 120 240 360 240 480 300 240 480 480
L 9.5 9.5 9.5 11 11 11 19 19 22 22 22 22 22 38 38 38 38 38 38 29 32 44 44 44 44 44 44 44 44 44 44 48.8 57.5 57.8 57.8 57.8 57.8 57.8 65.3 68.5 68.5 89
W 5.5 5.5 5.5 9.5 9.5 9.5 11 11 9.5 9.5 19 19 19 22 22 22 22 22 22 22 39 19 19 19 38 38 38 38 38 38 38 19 44 22 22 22 44 44 31.5 44 44 44
H 4.75 4.75 9.5 4.75 4.75 9.5 4.75 9.5 4.75 9.5 4.75 9.5 19 4.75 9.5 11 14.2 19 24 19 13 4.75 9.5 19 9.5 14.17 19 22. 23.6 29.2 38 19 33 4.75 9.5 14.72 9.5 19 11.8 9.5 19 19
Tare Weight (est.) Kg. (lbs) 0.1 (0.2) 0.3 (0.7) 0.2 (0.4) 0.2 (0.4) 0.4 (0.9) 0.3 (0.7) 0.4 (0.9) 0.8 (1.8) 0.4 (0.9) 0.5 (1.1) 1.1 (2.4) 1.3 (2.9) 1.8 (4.0) 1.9 (4.2) 2.7 (5.9) 2.8 (6.2) 3(6.6) 3.3 (7.3) 3.4(7.5) 3.2(7) 3.4(7.5) 1.7 (3.7) 2.4 (5.3) 3.3 (7.3) 7.8 (17.2) 8.6 (19) 9.4 (20.7) 9.9 (21.8) 10.2 (22.5) 11.0 (24.9) 12.5 (27.6) 5.2 (11.5) 15.8 (34.8) 4.3 (9.5) 5.1 (11.2) 5.8 (12.8) 11.0 (24.3) 13.0 (28.7) 8.5 (18.7) 12.2 (26.9) 14.3 (31.5) 16.8 (37)
July 2013
CARTON SPECIFICATION BCT. Burst Puncture Strength Resist. (Kg) (kPa) (J) 208 1320 6 208 1320 6 208 1320 6 243 1320 6 243 1320 6 243 1320 6 294 1320 6 294 1320 6 301 1320 6 301 1320 6 692 2180 12.8 692 2180 6 692 2180 6 737 2470 13.8 1179 2800 15.2 1179 2800 15.2 1179 2800 15.2 1074 2500 14.2 1074 2500 14.2 1074 2500 14.2 1074 2500 14.2 952 2470 13.8 1102 2500 14.2 1102 2500 14.2 1950 3524 20.2 1950 3524 20.2 1950 3524 20.2 1950 3524 20.2 1950 3524 20.2 1950 3524 20.2 1950 3524 20.2 1990 3524 20.2 2430 3524 20.2 2160 3524 20.2 2160 3524 20.2 2160 3524 20.2 2430 3524 20.2 2430 3524 20.2 2380 3524 20.2 2560 3524 20.2 2560 3524 20.2 2780 3524 20.2
Maximum Weight Per Box Kg (lbs) 15 (33) 15 (33) 15 (33) 15 (33) 15 (33) 15 (33) 15 (33) 15 (33) 15 (33) 15 (33) 15 (33) 30 (66) 60 (132) 30 (66) 60 (132) 60 (132) 60 (132) 60 (132) 60 (132) 60 (132) 60 (132) 30 (66) 60 (132) 60 (132) 60 (132) 60 (132) 210 (462) 250 (550) 420 (924) 420 (924) 500 (1100) 250 (550) 500 (1100) 120 (265) 250 (550) 250 (550) 500 (1100) 500 (1100) 500 (1100) 350 (770) 500 (1100) 500 (1100)
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions IMC Carton Number IMC320
Exterior Dimensions (mm) (in) L 2240
W 560
H 480
L W 89 22
H 19
Tare Weight (est.) Kg. (lbs) 9.1 (20)
CARTON SPECIFICATION BCT. Burst Puncture Strength Resist. (Kg) (kPa) (J) 2530 3524 20.2
Maximum Weight Per Box Kg (lbs) 350 (770)
Important note: To provide an almost complete overview on all currently used IMC cartons a full listing is provided. Nevertheless suppliers are highly recommended to use the carton types highlighted with bold letters as the first choice. Other listed IMCs may only be used after written approval from the responsible packaging engineer. All IMC cartons must meet the carton material and dimensional specification regardless from where purchased. 'HC' (High Cube) IMC cartons are only to be used for high cube ISO containers. Tolerance: Exterior dimensions must be maintained to +0.0 and -5.0mm (+0" and -0.2"). Note: * IMC011/031 are for Hardware and very small parts only, and consists of base + lid. # Recommended maximum load = 30kg. (62lbs) Conversion Factors: 1" = 25.4mm 1kg = 2.2lbs Maximum weight of a unit load including the pallet base must not exceed 500kg (1,100lbs). Asia Pacific Plants will also accept quarter keg boxes for hardware (229mm x 229mm x 127mm) cartons. Pallet dimensions should be 740mm x 740mm x 150mm.
6.4 ISO-MODULAR CARTON (IMC) SIZES – Europe & Asia Pacific Mixed unit loads of different parts and carton sizes ARE acceptable, the modular carton design allowing all cartons to be inter-stacked. Do not add empty cartons to the pallet stack to achieve a flat layer. Homogeneous unit loads are shown simply to illustrate relative carton size and orientation on the ISO-Modular pallet.
IMC010/011
IMC020
IMC030/031
IMC040
IMC050
IMC060
IMC070
IMC080
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
IMC090
IMC100
IMC110
IMC120
IMC130
IMC140
IMC150
IMC160
IMC170
IMC180
IMC190/193
IMC200/203
IMC220
IMC230
IMC240
IMC250
IMC260
IMC270
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
IMC290
IMC300
IMC310
Box Number IMC220 IMC230 IMC240 IMC250 IMC260 IMC270 IMC290 IMC300 IMC310 IMC320
IMC320
Carton Outside Dimensions millimeters (mm)
Pallet Dimensions millimeters (mm )
L
W
D
LxWxD
1460 1470 1470 1470 1470 1470 1740 1740 2240 2240
1120 560 560 560 1120 1120 1120 1120 1120 560
840 120 240 360 240 480 240 480 480 480
1470x1140x110 1470x1140x110 1470x1140x110 1470x1140x110 1470x1140x110 1470x1140x110 1740x1140x110 1740x1140x110 2260x1140x110 2260x1140x110
# Not all IMC carton sizes are shown as sketches. The IMC carton codes are also used to specify the packaging in Ford systems such as CMMS3 or ASNs etc. Please note that codes must be used as shown e.g. without any blanks or other characters in between.
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
7. Unit Load Consolidation and Shipping Guidelines Once the optimum export carton has been selected and is approved for your part - it is critical that you prepare and consolidate the cartons in the correct manner for shipment: 1. Unit loads must be constructed in accordance with the guidelines in section 6 2. Pallet bases must conform to the specification in section 8. 3. The following general shipping guidelines must also be adhered to:
Each carton must at least be labeled with Ford standard Odette or AIAG part number labels on two adjacent sides. For IMC cartons where height is less than 120mm (4.75”) the chosen label data format must be used but the label must be reduced to fit onto the side of the carton. Maximum height of any unit load must not exceed 1100mm (43") unless approved by Packaging Engineering. Reference section 6 to determine the appropriate maximum quantity of IMC boxes allowed on a pallet. If you supply more than one part number to Export Markets, mixed loads of various cartons on a single pallet is permissible to achieve a complete unit load. Carton flaps must be completely sealed with tape or spot gluing. Kraft paper tape is preferred over plastic tape to assist in carton recyclability. All modular carton loads must be secured to the pallet with plastic banding and/or clear plastic stretch wrap. A minimum of, four bands are highly recommended to avoid carton shifting during transit. For safety reasons, under no circumstances should steel banding be used. If stretch wrap is used, several rotations around the base of the pallet are required to avoid carton shifting. If you supply more than one part number to Export Markets, mixed loads of various cartons on a single pallet are permissible to achieve a realistic unit load, provided they are for the same plant destination. When shipping mixed loads on a single pallet ensure that the heavy load cartons are positioned on the pallet first with the lighter load cartons on the top. All IMC Unit Loads must be designed for double stacking of the same weight for overseas shipments and triple stacking for warehousing purpose (Exception: IMC197/IMC197HC must be designed to stack three high in an ISO container). Any deviation requires approval from the Ford packaging engineer.
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Ford M Motor Companny – Global Exxport Market Packaging P Terrms and Condiitions
7.1 GUIDE G E TO LO OAD CA ARTON NS ONT TO PAL LLET BASE B Bandiing & Strretch Wra apping:
Carton alignm ment:
Banding that passses comple etely unde er the pallett can be da amaged byy Fork Lift Trucks during ng operatio ons and m must be sufficiently s tight to ccontrol the stack witthout crea ating handlin deformation of the top carto on. It is reccommende ed that a spacer or lo oad spread der is used d on p edges. Stretch Wra apping is a an alternative to banding for un nit loads, p particularlyy for the top smallerr cartons o or light loads. The pllastic wrap pping shou uld be applied to pro ovide sufficcient strength to the pack and b be capable of retainin ng the carrtons in co orrect alignment with the b pallet base. Note: For F importts into Asia a Pacific & Africa Re egion, due e to varied climatic cconditions and temperrature varia ances, in particular p d due to condensation issues, it is required d to band and stretch wrap unit loads or to o put poly bag over the t U/L. Additional p packaging e elements (e.g. ( corner posts, cell partitionss, corner boards etc.) may be required as well to sstrengthen the unit loa ad stiffnesss.
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Ford M Motor Companny – Global Exxport Market Packaging P Terrms and Condiitions
MOST T COMMO ON ERRO ORS TO A AVOID: Pyramid Stacking
Pyra amid loading prevents oth her loads bein ng placed on to op, therefore reducing exxport cube utiilization.
Poor alignment prevents modular ccube and placces uneven loading on n the cartons increasing th he risk of crushing. The same resu ult occurs with h the placing g of heavy cartons (green discs) on top of light ca artons (red diiscs). Insufficcient banding alllows movem ment of the sta acked carton ns during transportattion.
AC ACCEPTAB ABLE
Able to o safely stackk in storage e and transit to same height as durable e equivalent
Max he eight of unit lload 100cm m Full Pe erimeter palle et require ed
Full perim meter pallet, reinforced d with under runners to o withstand handling fforces
U UNACCEPT TABLE
Collap psed stack Insuffiicient durab bility
1. Two way entry 2. Fiber pallet Use full perrimeter base with under
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No bandin ng of pallet
July 2013
Pyyramid load do oes not allow w sttacking
Banding g under pallet ba ase (restrictts fork access))
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Ford M Motor Companny – Global Exxport Market Packaging P Terrms and Condiitions
8. IS SO Mo odularr Pallett Spec cification All expo ort market shipmentss must conform to the e 980mm (39”) ( x 114 40mm (45”)) full perimeter pallet sspecificatio on below, designed specifically for ISO O containe er shipmen nts. Altern nate dimens sions othe er than listted are NO OT acceptable. Corrugated or alternate a p pallet materrials are nott acceptable unless approved byy Packagin ng Enginee ering.
Pallet Tyype Length h [L] Width [W] Height [H]
Dimenssions of avaailable Stand dard Palletss IMC CK160 1140 9 980 1 123
IM MCK161 1 1490 1 1140 123
IM MCK171 1740 1140 123
Any pallet length that excee eds 1800mm m in length h must be o of a stringe er or runner design in n order to o withstand d handling forces. Any pallet used in n conjunctio on with carrtons, with a larger fo oot print sizze than the standard IISO must repliccate the same design principles of the ISO O pallet exccept for foo ot print pallet, m dimenssions. EXPORT T 1750-Globaal
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
9. Phytosanitary and Packaging Material Selection Phytosanitary is about the protection of plants in the world against insect infestation. For this purpose the United Nations have developed measures to protect plants and to prevent the distribution of non domestic pests over the globe. These measures are compiled in the ISPM15 regulation. The ISPM15 requires all wood packaging material exported from one country to another country to meet these requirements based on the International Plant Protection Convention. Supplier's wooden packaging must comply with the ISPM 15 regulations when packing material for shipments to all export countries. Suppliers must investigate all Phytosanitary requirements and comply with any additional regulation that is specific to the country they are shipping to. Key Points These regulations also affect emergency expendable shipments, so even if you are currently using durable, you also need to comply with your emergency shipments with Phytosanitary rules. ll treated wood packaging material must be Acceptable marked with an official stamp identifying that the wood is debarked, the type of treatment used (DB-HT or DB-MB), the ISO country code where applied e.g. GB, DE etc. and the registration number of the body which applied Unacceptable it. (See sample mark). The wood packaging supplier is responsible for marking. Please note that the label should be outlined with border, as this is a mandatory requirement for certain regions (see above acceptable example). The requirements will not apply to wooden packaging material comprised wholly of processed wood such as plywood; fiberboard or similar products prepared using a high temperature, high-pressure process.
Ford may audit any shipments. Failure to send shipments in the correct packaging will result in demerit points issued against your supplier performance rating. Using non compliant packaging also may result in rejection of your material. Any cost associated with the rejection of material and / or repacking will be charged to you. The following website links should answer any questions you may have: http://www.fao.org/documents/show_cdr.asp?url_file=/DOCREP/006/Y4838E/Y4838E00.HTM International Phytosanitary Portal (IPP) - https://www.ippc.int/IPP/En/default.jsp Note: Heat treating pallets with steam is not an acceptable process for ISPM15 compliance.
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
10. Corrosion Prevention Overview Parts for export markets are more exposed to corrosion risks than domestic shipments. Corrosion can be caused by various circumstances, which may have no direct influence or obvious impact. Due to long shipping and staging times and extreme variations in both temperatures and humidity, parts for export markets have a higher risk of corrosion than domestic shipments. Environmental conditions can play a critical role in the manifestation of corrosion by accelerating any caustic elements on the part surface. Thus, it is critical the appropriate measures be considered when developing a corrosion inhibiting system for export shipments. Corrosion can be caused by various circumstances, many of which are inherent to manufacturing, handling and shipping processes. Corrosion inhibiting materials, such as VCI, must be used where rusting and corrosion is a risk. When developing a corrosion inhibiting system for your components, it is recommend the following measures be considered: component material properties (ferrous steel, etc.), part surface cleanliness and dryness (pack only dry and clean parts), part temperature (if possible, look to insure parts are ambient temperature before packaging), handling process (wear clean, lint free gloves when handling parts) and environmental conditions of the supply chain (temperature, humidity, volatility of climate conditions, storage conditions, transportation mode, etc.). Look to prevent part to wood, paper or corrugate contact to prevent acidic contamination that can cause corrosion. Suppliers who are in need for support to establish the appropriate corrosion protection method may address a third party who specializes in corrosion management/protection products and services, or their Ford packaging engineer. Some regions can provide an awareness guide for corrosion protection, which can give you an introduction to this subject but you have to consider: The selection of best suited corrosion prevention method for ensuring component quality till the point of use remains with you - the supplier of the product.
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
11. Final Export Packaging Checklist To ensure that you have used these Packaging Guidelines correctly please use the following checklist to tick off that all key steps have been undertaken: Note: Compliance with this checklist does not relieve you from the other obligatory content of these packaging terms and conditions but shall give you an overview on key steps. 1.
Have you obtained and read the latest Export Packaging Terms and Conditions document?
2.
Have you selected a provisional export packaging specification using the guidelines, and the table of available IMC cartons?
3.
Have you completed the GPP input or sent a Form EU1121/APA1121 proposal to Packaging Engineering for provisional approval?
4.
Have you received 'provisional approval' for this proposal through the GPP or by e-mail for EU1121E/APA1121 communication process?
5.
Have you used the appropriate printing, pallet base, stickers and handholes to be used when shipping this packaging?
6.
Have you selected appropriate supplier(s) that can provide each of the above and can support your shipping volumes and dates?
7.
Have you selected a packaging supplier that can provide the approved carton to the performance specification detailed in Table 1 or Table 2?
8.
Has appropriate corrosion protection method been selected to ensure part quality?
9.
Has appropriate training for warehouse staff been considered to ensure that consolidation and shipping guidelines are complied with?
10. Have you documented internal processes to ensure that export shipments are always shipped to the approved specification?
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
ATTACHMENTS Contents PAGE Attachment A: Export Market Packaging Frequently Asked Questions 1. IMC - General Requirements.......................................................
24
2. Quality – Supplier Performance Demerits, QRR .........................
25
3. Dunnage, Pallets, Box Strength, Quantities ................................
25
4. IMC Printing, Weight Discs, Handholes.......................................
26
5. Packaging Data - GPP, EU1121, APA1121 CMMS3 ..................
27
6. Packaging Performance Testing .................................................
28
7. Trial Shipments ...........................................................................
28
8. IMC Special Case Design ...........................................................
28
9. Special Packaging Design ...........................................................
29
10. Commercial Issues ....................................................................
29
Attachment B: Contacts 1. North America .............................................................................
30
2. South America .............................................................................
30
3. Europe .........................................................................................
31
4. Asia Pacific ..................................................................................
33
Attachment C: Recommended Packaging Suppliers 1. North America .............................................................................
34
2. Europe and Turkey ......................................................................
34
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
Attachment "A": Frequently Asked Questions
1. IMC - General Requirements Why are IMCs required for export shipments? The Ford IMC world wide export-packaging standard is required for all shipments that cross the ocean on ISO-Sea Containers in order to standardize consolidation packaging methods, maintain quality, maximize freight cube utilization, and to ensure that packaging is acceptable and adaptable to local market conditions. What are the key IMC requirements? Outside carton dimensions must conform to the Ford specified IMC sizes, IMC number printed on two sides of carton, IMC block pallet, Colored weight discs and handholes are used in accordance to the guidelines. Outside carton dimensions (L x W x H) must conform to the Ford specified IMC Sizes to allow unit load cubing using boxes from any supplier.
IM C
IM C
140
Colored weight discs are applied to two sides of the carton to notify operators how much weight is in each box. Operators can then determine the number of people required to manually handle each carton.
120
IMC specified block pallet design provides a "picture frame bottom" to evenly distribute weight of pallet along the perimeter of the cartons to fully utilize carton strength.
IM
0 C13
Colored weight discs are applied to two sides of the carton to notify operators how much weight is in each box. Operators can then determine the number of people required to manually handle each carton.
Who is responsible for implementing IMC packaging? It is the supplier's responsibility to work with their corrugated box and pallet sources to develop packaging, including interior dunnage, that will provide adequate strength, allow safe handling, and ensure product quality to the point of use. Which export destinations require IMC packaging? All overseas shipments require IMC packaging. How do I obtain updated copies of the latest IMC documentation? Go to: Covisint https://portal.covisint.com, Ford Supplier Portal, GTC Web-Guides
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
Attachment "A": Frequently Asked Questions (Continued)
2. Quality – Supplier Performance Demerits, QRR Why did I receive supplier delivery performance demerits for packaging? Ford packaging engineers will issue Supplier Delivery Performance Demerits to export suppliers if your company's material does not comply with the IMC specifications. Common NonConformance material includes: Non-IMC sizes, No IMC printing, No IMC pallet, collapsed loads with too much weight that require additional strength, and open-top pallet box containers that do not allow stackability within the ISO-Sea container. Can the Supplier Delivery Performance Demerits be rescinded? Once demerits have been issue by Ford Supplier Performance they can not be removed without clear evidence that supplier is not responsible for the concern. Why did our company receive a QRR (North American supplied parts only)? A QRR is a quality concern report generated by the affiliates in the export country. QRR's are quality concerns raised against parts that were damaged during transit. Typically packaging related QRR's are a result of Non-IMC packaging, collapsed loads, inadequate dunnage, etc. Suppliers that receive packaging related QRR's are required to work with Ford Packaging Engineering and Ford IEO Quality to determine the root cause of the problem and revise their export packaging as needed. Remember, it is the supplier's responsibility to design export packaging to ensure quality to the end point of use. What is an ISPR and how do I need to respond to that? An ISPR (Inappropriate Shipping Practice Report) is issued by the receiving plant and followed up through the material handling & packaging engineer when material was inappropriately packed causing issues in transport logistics. Suppliers are required to adhere to the specified packaging to avoid concerns raised through an ISPR and to furthermore avoid de-merit procedures.
3. Dunnage, Pallets, Box Strength, Quantities What dunnage (corner posts, cell dividers, bags, foam, VCI, etc) is required? It is the suppliers' responsibility to determine the appropriate dunnage needed to ensure quality. Can I use alternative pallet materials, designs, or sizes? No, all pallets must be made of wood. Corrugated and plastic pallets are not allowed for export shipments. All standard IMC sizes must be shipped on the IMC 1140x980x127mm; 39" x 45" x 5" block pallet, and must meet the International Plant Protection Convention (IPPC) ISPM15 specification; Go to the web sites indicated in the document for details. Are IMC pallets required if I'm only shipping a few boxes? Yes, all shipments made to the export consolidator are required to ship on the IMC specified block pallet.
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
Attachment "A": Frequently Asked Questions (Continued) What if our parts are too heavy for the standard IMC boxes? Suppliers that exceed the Ford Packaging Engineering recommended weight limits are required to add additional strength to the carton in terms of increased board grade, corrugated box design, dunnage, or corner posts, etc. Remember, the responsibility for ensuring component quality from your plant to the point of use remains with you – the supplier of the product. It is the suppliers' responsibility to work with their corrugators to determine the appropriate packaging strengths to apply to IMC boxes. If board grade is increased (i.e. from double wall to triple wall) remember that the outside dimensions must continue to meet the IMC specified dimensions. In other words, as board grade increases, the inside dimensions will decrease while the outside dimensions must stay the same. Please also ensure that the stackability requirements (as per section 7) are met. How do I determine an appropriate standard carton quantity? Standard packaging quantities need to be established based on the following principles: annual estimated volume for the program, line feed requirements, FPS right sizing principles, weight limit requirements, and optimum carton density rather than a specific quantity limit. What if I can't achieve 95% cube utilization within the carton? Ford Packaging Engineering understands that dictated carton sizes do not accommodate all parts. If you are having trouble selecting an IMC pack that optimizes density please contact Ford Packaging Engineering. Digital photos of your part, current packaging, and proposed packaging are often required for Ford to evaluate your situation. What if my export releases have large fluctuations? Since there are often large fluctuations in release quantities for export part-by-part programs, IMC standard pack quantities need to be defined to accommodate your average export release quantity. Once a standard pack quantity is defined, what if I get an order for fewer pieces? Once a standard pack is defined, all shipments must be made to accommodate a minimum of one carton. In case of any phase out or pre build shipment the release quantity may be less than the carton pack quantity and needs to be shipped as per release. What if my unit load quantity exceeds the average weekly requirements? Your packaging specification (EU1121, APA1121 or GPP) must be submitted based on a full unit load quantity. However, your release quantity will be in either carton, layer or unit load quantities.
4. IMC Printing, Weight Discs, Handholes Why do I have to print the IMC number on the box? The IMC number is used by Ford consolidation centers to sort IMC and Non-IMC material. The number is then used to determine the appropriate cubing method to apply when building up unit loads. What happens if the IMC number is not printed on the box? Export consolidator will not recognize your box as IMC compliant. The box will then be placed in a one-way expendable crate to ensure quality. The crating process may then trigger a supplier performance demerit.
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
Attachment "A": Frequently Asked Questions (Continued) Should the IMC number be on adjacent or opposite sides? Either is acceptable. Most suppliers print on opposite sides of the box along the length panel of the box. How large does the IMC printing have to be? The size of the printing depends on the IMC box number used. Typically the printing is around 2"/50 mm high. However, smaller boxes such as the IMC010 use smaller printing. It is important that the printing is located in the center of the box to avoid being covered up by labeling and to make sure it is highly visible for the consolidation center operators. What are the Weight Disc specifications? Weight Discs like the IMC printing are usually around 2"/50 mm. Slightly smaller or larger discs (1"/25mm-3"/76 mm) are also acceptable. Are Weight Discs and Handholes required for unit load sized boxes (IMC190 and above)? No. Weight Discs and Handholes are only required for IMC100 through IMC190 cartons How do I determine the correct number of Handholes required? Follow the chart listed in the IMC guidelines. The number of Handles correlates to the IMC Weight Disc color.
5. Packaging Data - GPP, EU1121, APA121 CMMS3 What is the purpose of submitting a GPP input or EU1121or APA1121? These forms are used by Ford Packaging engineering to evaluate if your proposed dimensions and weights are in line with the IMC strategy. If these characteristics are in line with the guidelines "provisional or final approval" will be granted. If Ford approved my packaging specification and it fails during implementation is it Ford's responsibility? No, approval means that Ford Packaging Engineering agrees that your export packaging proposal meets Ford box dimensions and weight limit requirements. It is the suppliers' responsibility to ensure that the appropriate board grades, dunnage, corrosion protection, etc is implemented to ensure quality. Do I need to input my packaging data into CMMS? All suppliers located in North and South America are required to input their export packaging data (e.g. all type of IMC packaging codes) into the DAIA screen under the left hand side of the screen where it indicates "Returnable & Export Containers Dtls". All suppliers located outside North or South America but shipping into North or South America are required to input their packaging data on the right hand side of the screen under "Expendable Packaging Unit". For Ford of Europe and Ford Asia Pacific regions, the DAIA CMMS screen will be maintained by the Ford packaging engineer. Who do I contact if I have questions regarding CMMS? Contact your Supply Chain Follow-up Analyst
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The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's Global Information System II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited. This release replaces the previous July 2012 version. Globally Page 27 of 36 Uncontrolled When Printed
CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
Attachment "A": Frequently Asked Questions (Continued)
6. Packaging Performance Testing Is IMC packaging testing required prior to implementation? Testing is only required as needed. Unless otherwise directed by Ford it is up you, the supplier, to determine the amount and types of testing that will be needed to ensure quality shipments to export markets. How do I conduct testing? As the supplier, you are the expert on your specific parts sensitive features. It is up to the supplier to determine the appropriate testing methods and work with your preferred testing labs to adequately test export packaging for ocean shipments as needed.
7. Trial Shipments How should I conduct a trial shipment? Ford Packaging Engineering highly recommends that any trial shipment be shipped in accordance to your export releases. It is not recommended that you ship material to the export consolidator that does not satisfy a current release. If you conduct a trail shipment, be sure to contact Ford Packaging Engineering. Failure to contact the appropriate engineer will result in your package flowing through the transportation network without inspection.
8. IMC Special Case Design What if all IMC sizes don’t accommodate my part, when is a Special Case IMC allowed? Special Case ISO-Modular Cartons are only allowed when none of the IMC sizes will meet the unique needs of a specific part. Special Case ISO-Modular Cartons are required to follow the same requirements stated in the guidelines with the exception of the outside carton dimensions, corrugated printing and the appropriate pallet size. How do I design an optimum Special Case IMC? Special case cartons are designed by altering required ISO-Modular Carton dimensions to meet the needs of specific parts. Remember, the primary objective of the IMC program is to facilitate direct material loading into the ISO-Sea container. This means that you must select the appropriate packaging material and dimensions to ensure stackability within the ISO-Sea container. The 45" (or 90") width is the most critical dimension due to the fact that the width dimension of an ISO-Sea Container is 90". This dimension must be held in order to load cartons side by side in an ISO-Sea Container. The 43"/1100mm maximum unit load height is second critical dimension because of the ISO-Sea Container usable opening of 86". The length is least critical dimension is of the carton. Try to design the length as close to 38, 51, 57, 66, 77, and 89 as possible. All Special Case IMC Sizes must be approved by Ford Export Packaging Engineering. Are IMC-Special Case cartons only allowed as unit load sized cartons? Typically, Yes. Most IMC-SC designs involve unit load scenarios. Deviating small carton dimensions, causes the entire "modular" theory of the IMC strategy to become void. The only way a small carton dimension such as the height could be approved, as a special case design would be if the release quantities were always in full layer quantities or full unit load quantities. EXPORT 1750-Global
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The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's Global Information System II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited. This release replaces the previous July 2012 version. Globally Page 28 of 36 Uncontrolled When Printed
CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
Attachment "A": Frequently Asked Questions (Continued) Can I simply label my current packaging as IMC-Special Case? Absolutely NOT! Unless packaging engineering approves a special case design, it will not be acceptable. Inappropriately labeled cartons will be subject to Supplier Performance Demerits. Are Weight Discs and Handholes required for unit load sized IMC-SC designs? No, Weight Discs and Handholes are only required for manually handable cartons. What are the IMC Special Case Printing requirements? IMC cartons need to be labeled with the appropriate IMC number. Any Special Case cartons must substitute the required ISO-Modular Carton Number with the letters "SC" (Special Case). Example: IMC200 to IMCSC
9. Special Packaging Design What if my parts require packaging other than corrugated carton?: If your part requires special packaging please contact your Ford Packaging Engineer to discuss and select another alternative (e.g. returnable container, expendable steel rack, wood crate, etc). If the alternative pack requires a different commercial agreement this must be approved by the Ford Buyer prior to packaging approval.
10. Commercial Issues Is there a Ford preferred source to procure IMC boxes and pallets? There are specialized packaging companies who can provide you with IMC standard cartons, IMC special case cartons, pallets and accessories for your packaging. Contacts for some of these packaging companies can be found in the attachment. Is there a Ford preferred source to procure VCI for Rust sensitive parts? There are specialized packaging companies who can provide you corrosion prevention materials and corrosion management expertise. Some company contacts can be found in the attachment What if there are commercial issues regarding implementation of IMCs? All commercial issues must be handled through your designated Ford buyer. The IMC program has the support of Ford Purchasing management worldwide. How do I manage different Packaging for different locations? This is a supplier issue that must be handled internally. Your company needs to recognize different packaging requirements based on the ship to location even if the Ford part number is the same. Suppliers are encouraged to contact their Ford packaging engineers to discuss solutions for common packaging if applicable. Will Ford assign separate part numbers? No. Ford will not assign different part numbers because of different packaging requirements for different locations. It is up to the supplier to handle this requirement internally.
EXPORT 1750-Global
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The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's Global Information System II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited. This release replaces the previous July 2012 version. Globally Page 29 of 36 Uncontrolled When Printed
CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
Attachment "B": Contacts
1. North America Contact List Ford Motor Company March 2013 North America Packaging Contact List New Model Programs Plant / Program Cuautitlan Assy Plant / B299 evo Flat Rock Assy Plant / CD4.1 & S550 Hermosillo Assy Plant / CD4.1 Kansas City Assy Plant / V363 Louisville Assy Plant / C489 & C520
Vehicle Operations Name Caleb Conradi Karl Bacon Karl Bacon Michael Vanwert Leyanna DiGiovanni Leyanna DiGiovanni
Phone (313) 845-2531 (313) 390-4485 (313) 390-4485 (313) 594-7342 (313) 390-4487 (313) 390-4487
Name Jamie Dugan Arian Torres Mark Phillips Dan Eichholtz Raymond Baillargeon Fred Ochtel Marisol Leon Brian Mcaninch Chris Fenner Jeff Haysley Todd McFarland Steve Keating Raj Ramsaroop Dave Eaton
Phone (773) 322-1948 52-555-8997522 (313) 845-1468 (313) 845-1820 (313) 743-2317 (313) 502-7621 52-662-2598893 (816) 459-1552 (816) 459-1634 (502) 429-2314 (502) 357-6150 (734) 467-9488 (905) 853-3536 (440) 282-1280
Existing Programs Plant / Program Chicago Assembly Plant Cuautitlan Assembly Plant Dearborn Truck Plant Detroit Chassis Plant Flat Rock Assembly Plant Hermosillo Assembly Plant Kansas City Assembly Plant Kentrucky Truck Plant Louisville Assembly Plant Michigan Assembly Plant Oakville Assembly Plant Ohio Assembly Plant
[email protected] [email protected] [email protected] [email protected] [email protected] [email protected]
Vehicle Operations
New Model Programs
Email
[email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected]
Powertrain Operation - Engine
Plant Chihuahua Engine Plant
Name (I-4) Gustavo Baca (V8 Diesel) Fernando Ruiz Cleveland Engine Plant Drew Doty Dearborn Engine Plant Darren Tatum Essex Engine Plant Brad Walker Lima Engine Plant Darren Tatum Rawsonville Componet Plant Steve Birman Brad Walker Romeo Engine Plant Brad Walker Windsor Engine Plant Brad Walker
EXPORT 1750-Global
Email
July 2013
Phone 52-614-1580366 52-614-4294062 (313) 390-1542 (313) 390-4510 (313) 390-5058 (313) 390-4510 (313) 248-3147 (313) 390-5058 (313) 390-5058 (313) 390-5058
Email
[email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected]
GIS 1:26.06, C+12
The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's Global Information System II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited. This release replaces the previous July 2012 version. Globally Page 30 of 36 Uncontrolled When Printed
CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
Ford Motor Company March 2013 North America Packaging Contact List Existing Programs
Powertrain Operation - Engine
Plant Chihuahua Engine Plant
Name (I-4) Gustavo Baca (V8 Diesel) Fernando Ruiz Cleveland Engine Plant Eric Jurs Dearborn Engine Plant Darren Tatum Essex Engine Plant Joe Bondy Lima Engine Plant (D35/7) Gerald Wurth (Nano) Kyle Klein Rawsonville Componet Plant Ed Lustenader Romeo Engine Plant Lori Clark Windsor Engine Plant Enzo Grado
Phone 52-614-1580366 52-614-4294062 (216) 676-3548 (313) 390-4510 (313) 910-9526 (419) 226-7075 (419) 226-7056 (734) 484-8482 (586)752-8001 (519) 257-2362
New Model Programs Plant Livonia Transmission Plant Sharonville Transmission Plant Sterling Plant Van Dyke Transmissioj Plant
Email
[email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected]
Powertrain Operation - Transmission Name John Rumschlag Brandon West Brandon West Kevin Walsh
Phone (313) 323-1412 (313) 390-1935 (313) 390-1935 (313) 594-1688
Existing Programs
Email
[email protected] [email protected] [email protected] [email protected]
Powertrain Operation - Transmission
Plant Livonia Transmission Plant Sharonville Transmission Plant Sterling Plant Van Dyke Transmission Plant
Name Ken Sammons James Whitlock Matthew Smith Courtney Edmunds Marty Schmuckel
Phone (734) 523-5863 (513) 782-7037 (586) 405-8177 (586) 826-6183 (586) 826-6166
Email
[email protected] [email protected] [email protected] [email protected] [email protected]
2. South America Contact List March 2013 Ford Motor Company South America Packaging Contact List Responsibility
Name
Address
Phone
Email
Brasil Vehicle & Mauricio Argentina Godone Operations
AV DO TABOAO, 899, Tel: +55 11-4174 9655 Sao Bernardo de Campo
[email protected] Fax +55 11-4174 8969 SP, CEP 09655-900 Brasil
Brasil Powertrain Operations
Leonardo Fujioka
Avenida Charles Tel: +55 12-3625 7038
[email protected] Schneider, 2222, Taubate Fax +55 12-3625 7293 SP, CEP 12040-001 Brasil
Venezuela Operations
Morella Ruiz
Avenida Henry Ford, Zona Tel: + 58-241-8746372 Industrial Sur, 354; Valencia, Carabobo; Fax + 58-241-8746276 Venezuela
EXPORT 1750-Global
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[email protected]
GIS 1:26.06, C+12
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CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
3. Europe Contact List Ford Motor Company March 2013 European Packaging Contact List Vehicle Operations
Always quote your 5 digit GSDB supplier code when communicating with MH&PE and Container Service Providers
All 'B' Car Responsibility Name New Model Programs MH&PE VO Klaus Kiesewetter Packaging Coordinator Jörg Honsdorf Rob Argles Phill Scott Volkan Aydinlar Cologne Plant Karin Monix Pastorela Mihai Craiova Plant
Phone +49 221 901 2153 +49 221 901 4897 +44 1268 402541 +44 1268 401016 +49 221 902 9721 +49 221 901 3524 +40-372-516421
Email
[email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected]
All 'C' Car Responsibility Name Phone New Model Programs MH&PE VO Rob Liggins +44 126840 2538 Packaging Coordinator Cliff Graham +44 126840 2654 Bill Clissold +44 126840 2286 Holger Busch +49 221 901 6803 Stephan Peschmann +49 221 901 6720 Markus Krueger +49 221 901 8350 Jean-Marie Delettre +49-6831-924658 Saarlouis Plant Jacinto Azorin Martin +34 96 1791226 Valencia Plant Nerea Fernández de Liger +34 96 179 2581 Beatriz Yaqüe Aparicido +34 96 179 1768
Email
[email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected] [email protected]
All 'CD' Car Responsibility New Model Programs MH&PE VO Packaging Coordinator Genk Plant (PTA) Genk Plant (MS&B)
Name Brett Stevens Rainer Arend Peter Peters Jean-Marie Withofs Edwin Coemans
Phone +44 126840 1794 +49 221 901 6789 +32 89 616798 +32-89-616784 +32-89-619896
Email
[email protected] [email protected] [email protected] [email protected] [email protected]
Name Geoff Chamberlain Holger Busch Yildirim Yolcu David Holloway
Phone +44 1268 40 1013 +49 221 901 6803 +90-262-3155547 +44 2380 587690
Email
[email protected] [email protected] [email protected] [email protected]
All Transit Responsibility New Model Programs MH&PE VO Packaging Coordinator Turkey Plant Southampton Plant
FordSollers Packaging Contact List Responsibility New Model Programs MH&PE Packaging Coordinator St Petersburg
EXPORT 1750-Global
Name Yuri Babain Pavel Eroshkin Maxim Mescheryakov Yana Kosenko
July 2013
Phone +7-495-7459700 +7-495-7459217 +7-495-7459700 +7-812-3467151
March 2013
Email
[email protected] [email protected] [email protected]
[email protected]
GIS 1:26.06, C+12
The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's Global Information System II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited. This release replaces the previous July 2012 version. Globally Page 32 of 36 Uncontrolled When Printed
CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
Ford Motor Company
March 2013
European Packaging Contact List Existing Programmes - European PTO Engine Packaging Engineering Contact List
Current Engines
Name
Email
2L & 2.2L Puma
Kevin Cole
[email protected]
3L V6 Lion & 1.8D
Steve Tutte
[email protected]
1.4L & 1.6L Tiger
Andrew Daly
[email protected]
Thorsten Heidenfelder Ioan Manuel Mihulescu
[email protected] m
Plant
Dagenham Engine Plant
Cologne Engine Plant Craiova Engine Plant
1.0L Fox; 1.5L Sigma
Valencia Engine Plant
1.8L, 2L & 2.3L i4's
Bridgend Engine Plant
1.2L, 1.4L & 1.6L Sigma & 5L V6 AJ133; AJ126
1.0L Fox
Positio n
[email protected]
Manolo Navarro Gonzalez
[email protected] om
Elvira Romaguera Martí
MROMAGUE@ford. com
Hommie Parvini
[email protected]
Brett James
[email protected]
Senior Packaging Eng Senior Packaging Eng Senior Packaging Eng Packaging Eng Mat.Handl. Engineer Senior Packaging Eng Packaging Eng Senior Packaging Eng Packaging Eng
Mail Symbol
Tel No.
+44-208-526 GB 3/205 2262 +44-208-526 GB 3/205 2202 +44-208-526 4055
GB05/00 B-G02-A
+49-221-901 D-NW/E6396 116 +40-372RO-01 516178 +34-96-179 3016
E-AM/LF40
+34-96-179 1383
E-AM/LF41
+44 1656 67 2537
GB 25/117
+44 1656 67 2493
GB 25/117
New Programmmes - European PTO Engine Packaging Engineering Contact List
Plant
All European Engine Plants
Cologne & Craiova Engine Plants Craiova Engine Plant Dagenham Engine Plant Dagenham Engine Plant Bridgend Engine Plant Bridgend Engine Plant
EXPORT 1750-Global
Future Engines All Future Projects
1.0L Fox
Name
Email
Position
tbe
tbe
Supervisor
Caroline Guest
[email protected]
Senior Packaging Eng
Errol Noel
[email protected]
Packaging Eng
Danny Clark
[email protected]
Packaging Eng
[email protected]
Packaging Eng
2L & 2.2L Puma EU5, Lion EU6
Andrew Smallman Aron McGinness
Tiger EU6
Danny Clark
5L Sigma
3L V6 AJ126 1.5L Sigma
Leighton Johnson Andrew Smallman
[email protected] Packaging Eng
[email protected]
Packaging Eng
[email protected]
Packaging Eng
[email protected]
Packaging Eng
July 2013
Mail Symbol
Tel No.
+44 1268 40 1682 +44 1268 40 1684 +44 1268 40 1836 +44 1656 67 2056 +44 1268 40 1022 +44 1268 40 1836 +44 1656 67 2056 +44 1656 67 2056
GB 15/4AM04 GB 15/4AM04 GB 15/4AM04 GB 25/117 GB 15/4AM04 GB15/4AM04-A GB 25/117 GB 25/117
GIS 1:26.06, C+12
The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's Global Information System II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited. This release replaces the previous July 2012 version. Globally Page 33 of 36 Uncontrolled When Printed
CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
4. Asia Pacific Contact List Ford Motor Company APA Packaging Contact List
Vehicle Operations Responsibility
'B' Car - New Model Launches
'C/ CD / D' Car - New Model Launches
'T / U / V' Car - New Model Launches
March 2013
Always quote your 5 digit GSDB supplier code when communicating with MH&PE and Container Service Providers
Name
Phone
Email
Ram Kumar
+91 4467403788
[email protected]
Pragadeesh
+91 4467403349
[email protected]
Poonsak
+66 38954111-4205
[email protected]
Eric
+86 2551187905
[email protected]
Arun Prasad
+91 4467403347
[email protected]
Ananth Padmanabhan
+91 4467403210
[email protected]
M Usha
+91 4467407156
[email protected]
Sridhar S
+91 4467403348
[email protected]
Santosh KV
+91 4467403335
[email protected]
PTO Operations
Responsibility All Models
Name
Phone
Email
M Usha
+91 4467407156
[email protected]
RSR/ESR - VO & PTO
Responsibility All Models
Name
Phone
Email
Praveen
+91 4467403340
[email protected]
John Jacob
+91 4467407193
[email protected]
Name
Phone
Email
Sundaresan
+91 4467403345
[email protected]
Arun Prasad
+91 4467403347
[email protected]
Name
Phone
Email
Arun Prasad
+91 4467403347
[email protected]
Concern Handling - VO
Responsibility All Models
Concern Handling - PTO
Responsibility All Models
EXPORT 1750-Global
July 2013
GIS 1:26.06, C+12
The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's Global Information System II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited. This release replaces the previous July 2012 version. Globally Page 34 of 36 Uncontrolled When Printed
CONTENT
Ford Motor Company – Global Export Market Packaging Terms and Conditions
Attachment "C": Recommended Packaging Suppliers
1. North America March 2013 Name
Name
Packaging Corporation Dave Cislo of America – IMC Standard Corrugated Cartons
Function
Kamps – Export Block Pallets (MI, IN, KY, OH & IL)
Email
IMC Orders (734) 414-7556
[email protected]
Sales Packaging Corporation Gary Thompson of America – IMC Christopher Pannecouck Sales Special Case Corrugated Designs Packaging Concepts & Steve Ford Design – IMC Special Case Corrugated Designs
Phone
(734) 558-1356
[email protected] (734) 414-7550
[email protected]
Sales
(248) 640-6337
[email protected]
Mike McMillan
Sales
(734) 915-0033
[email protected]
Steve Gulda
Sales
(248) 881-4165
[email protected]
Northern Technologies – VCI Rust Inhibitor
2. Europe and Turkey March 2013 Name SCAdelta – IMC Standard Corrugated Cartons or Sheet Board
Name Function Phone Email Orders/Commercial +44-145-5892987
[email protected] Emma Kimberley Richard Barker Technical/Design +44-145-5892972
[email protected] Locations: http://www.scapackaging.com/en/sca-packaging-locations/ SCAdelta can also supply IMC carton sheet board to your packaging supplier. For all IMC and sheet board orders please contact the above SCAdelta personnel:
EXPORT 1750-Global
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The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's Global Information System II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited. This release replaces the previous July 2012 version. Globally Page 35 of 36 Uncontrolled When Printed
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Ford Motor Company – Global Export Market Packaging Terms and Conditions
3. Asia Pacific & Africa March 2013 Markets
India
Supplier Name Panoply Packagings
Supplier Contacts Rajendra Bafna
Address
Shangang Industrial Park, Yangshe, Zhangjiagang, 215638, China
Jack He
Tri-Wall
Viki Wu
HSL International
Ms.Pornpen HSL international Company Ltd Woracharttrakul 19/2 MU 4 THA KHAI MUEANG Team Leader CHACHOENGSAO Marketing
China
K.Jatupat Tri-Wall
South Africa
Telephone
Panoply Packagings PVT Ltd Tel: +91 44 27107300/01/02 panoplypackagings@g Survey No 205 & 206, Aarneri Village, Mobile: +91 98401 54033 mail.com Pondur B.O, Sriperumbudur – 602105.
Hangyu
Thailand
E - Mail
hezhong@hangyupack. Tel: 86-86-512-58548236 com Fax: 86-512 56766891 http://www.hangyupack Mobile: 86-133-8229-9848 .com
Rm.A5,20F, Jiangsu Building, No.528,
[email protected] Laoshan Road,Pudong, Shanghai, http://tri-wall.com.cn 200122, China
Tel: 86-21-3375 8856 Fax: 86-21-3375 4100 Mobile: 86-13915832231
[email protected] Tel : +66 038 847 507-9 #501 .th Fax : +66 038 847 510
[email protected] Mobile : +66 0818616788 m
Triwall Packaging Ltd 99/24, Moo 10, Bypass Chonburi
[email protected] Pattaya Road
[email protected] Tambol Nongkhom, Amphur Sriracha, Chonburi, Thailand - 20230.
Tel : +66 038 339393-96 Fax : +66 038 339397 Mobile : +66 038 863155988
Box Makers
Grand Brown
Box Makers ,Seaview, Port Elizabeth,
Tel : 041-3781735
[email protected] Fax : 041 378 2599 a Cell : +27826514833
PTA Box
Jean Jansen
PTA BOX, 424 Van Riebeck street Hermanstad Pretoria ,
[email protected]
EXPORT 1750-Global
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Tel : 012 379 9057 / 9 Fax : 012 377 2894 Cell : +27823762315
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The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's Global Information System II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited. This release replaces the previous July 2012 version. Globally Page 36 of 36 Uncontrolled When Printed
