EB73.03.160
Parts and accessories packaging
/D
________________________________________
Standard ________________________________________
Status
Binding
Important Note : This document has been translated from the French version. In the event of any dispute, only the French version is referred to as the reference text and is binding on the parties
Purpose
Define the specifications relative to the packaging of parts and accessories of the Renault group. This Specification applies to : Renault spare parts, including standard exchange parts Renault boutique parts, products and equipment Renault and Renault boutique accessories , MOTRIO parts IXELL products and equipment All other ranges of products distributed by DAV intended for RENAULT spare and accessories stores worldwide. This standard does not apply: Direct flow products ON-ROAD products
Scope
Renault group
Issuer
Confidentiality
Approved by
© RENAULT 2001
01382
:
Parts and Accessories Logistics Division
Non-confidential
Function
Signature
Source : PEGI Renault
Date of application
Page :
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EB73.03.160
D. MAINGUY
© RENAULT 2001
01382 Parts and Accessories Manager
Source : PEGI Renault
/A
01/2012
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EB73.03.160
/A
Version history Version Update A B
12/2001 04/2007
C D
01/2012 05/2013
Subject of the main modifications Creation. The standard NF H50-009 is cancelled and replaced by EN 13698-1 Update Update
Author Th. WEKSTEEN C.GARAT J. NAGAWA J. NAGAWA
Replaces
EB73.03.160 /B du 06/2007
Available from
Internal Renault, via Intranet : https://collaboration2.renault.com/eRoom/FAC_KORP1_38/PackagingPartsandAccessories External Renault, via Internet : portal supplier – logistics
Documents quoted
Regulations
Codification
ICS :
Class
E73
Key words
Package, packaging
Language
English
: Décret n° 98/638, Directive n° 94/62/CE, Directive n° 96/59/CE, Directive n° 97/129/CE. International : ISO 14021, ISO 14021 , ISO 7000, ISO 780. European : EN 13698-1. French : NF Q 12-008, NF Q 12-009. CNOMO : Renault : EB73.08.100. Other in-house doc. : Other external doc. : DIN 6120-1, DIN 6120-2, GALIA EMB.1, GALIA ETI 1, GALIA ETI 9, GALIA ETI.1.
55.040 ; 55.180.10 ; 55.180.20 ; 55.020
(1) Assisted in authoring the document Parts and Accessories Department
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Contents Page
1
General specifications.............................................................................................................. 5
1.1 1.2 1.3
Glossary ........................................................................................................................................................ 5 Purpose of the document ................................................................................... Erreur ! Signet non défini. Packaging validation process between the Supplier and Renault ................................................................ 5
2
Packaging engineering............................................................................................................. 6
2.1 2.2 2.3 2.4
Products groups recommendations .............................................................................................................. 6 Selection of a packaging ............................................................................................................................... 6 Packaging level or ESN (Negociated Standards) ......................................................................................... 8 General packaging engineering .................................................................................................................. 10
3
The main packaging product groups .................................................................................... 15
3.1 3.2
Plastic bags and film ................................................................................................................................... 15 Cardboard boxes and containers ................................................................................................................ 17
4
Transport and handling packaging (level 4) ......................................................................... 17
4.1 4.2 4.3
Standard Renault re-usable packaging ....................................................................................................... 17 Pallets .......................................................................................................................................................... 19 Box-pallets ................................................................................................................................................... 25
5
Environmental specifications ................................................................................................ 26
5.1 5.2
General ........................................................................................................................................................ 26 Specific rules ............................................................................................................................................... 26
6 Useful addresses .................................................................................................................... 30 7 List of documents quoted ...................................................................................................... 30 Appendix 1 : Dimensions of non reusable packaging (Galia standard) ........................................... 31 Appendix 2 : Palletization of non reusable packaging in GALIA standardized cardboards ........... 34 Appendix 3 : Invoicing packaging sorting and touch-ups ................................................................. 33 Appendix 4 : Derogation ...................................................................................................................... 34 Appendix 5 : Packaging proposal sheet ......................................................... Erreur ! Signet non défini. Appendix 6 : How to fill-in the packaging proposal sheet ................................................................. 36 Appendix 7 : List of available product group recommendations ...................................................... 39 Appendix 8 : GALIA label specimen ................................................................................................... 40 Appendix 9 : VCI Anti-corrosion protection label specimen ............................................................ 41 Appendix 10 : Numbering and abbreviation system ......................................................................... 42 Appendix 10 : Compatibility of plastics ............................................................................................. 43 Appendix 12 : Mix packing list specimen .......................................................................................... 33
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1
General specifications
1.1
Glossary
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Annexe 11 normative
DAV : Parts and Accessories Division DLPA : Parts and Accessories Logistics Division DIL : Logistics Engineering Division RNPO : Renault Nissan Purchasing Organization
1.2
Purpose of the document The described standards define the technical packaging rules for RENAULT parts and accessories that all RENAULT suppliers agree to comply. Provider defines as soon as possible, with this document and the applicable recommendations family, the appropriate packaging to its product, with constant seeking of optimization of the overall logistics cost. Then, the supplier fills in the packaging proposal sheet as explained in paragraph 2.3 and send back to its logistic contact person. No deliveries of parts and accessories can be done until the technical validation of the packaging proposal sheet by DIL and the economical validation by RNPO is made. The supplier commits to inform DIL Packaging department and also P&A Purchase Department (through a new packaging proposal) in case of economic or legislative evolution or technical innovation that may lead him to modify all or part of its packaging. All deliveries must match with : - Purchase general conditions - Applicable quality process - The validated packaging proposal sheet In case of packaging issues (cardboard boxes supply, partial deliveries…) DIL Packaging Department may edit derogations. This is a temporary document that can apply only to levels 3 and 4 of the packaging (Appendix 4). For any issue impacting levels 1 and 2, supplier has to get in touch with Renault procurement team so as to obtain a “delivery authorization”. Detail of invoicing relating to packaging noncompliance with this document is given in Appendix 3. Any derogation to the specifications noted in this document must be subject to a formal agreement that can only be delivered only by DIL P&A.
1.3
Packaging validation process between the Supplier and Renault For each new product, a duly documented packaging proposal sheet must be submitted to DIL packaging department for approval.
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Annexe 11 normative
A specimen of packaging proposal sheet is given in Appendix 5 Recommendations how to fill in the proposal sheet are described in Appendix 6 Furthermore, all additional documents enabling approval are recommended : palletization plan, pictures, packaging process, ....
VENDOR SUPPLIER SEND DOCUMENTED PACKAGING PROPOSAL
PACKAGING COORDINATOR TECHNICIAN TECHNICAL APPROVAL YE S PURCHASING LOAD PURCHASE CONTACT
NO
FINANCIAL APPROVAL YE S
NO
2
Packaging engineering
2.1
Products groups recommendations In addition to this standard, some recommendations define the packaging to be used for certain products groups. List of available product group recommendations : see Appendix 7
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2.2
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Selection of a packaging
Are there recommendations for the product group? N O
YE S Use the recommended packaging
Are you delivering a similar product with packaging approved by Renault? N O
YE S Apply the same packaging
Do the product characteristics correspond to the Descriptions in descriptions in the the tables tables below? YE N S O Send the packaging Contact the proposal to the relevant technician packaging relevant coordinator packaging technician coordinator
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Annexe 11 normative
LEVEL 1 PACKAGING Type of product and function of the packaging
Example of product
Product that is not fragile or and not is not appearance sensitive. Identification
Metal wheel, Exhaust system, tanktank
Packaging to be used
Label only (stuck flat)
Appearance sensitive product and small parts. Hub cap, lining Protection against grease, scratches and dust .
Plastic bag, bag trays
Product that needs to be packed flat
Cardboard board under underretractable retractablefilm film
Seal
Fragile product. Radiator, starter, lip seal Cardbox Radiator, transmission, transmission, starter, Cardboard box Must against impacts and and damage Mustbe beprotected protected against impacts damage lip seal box
Conditionstoàbe respecter Conditions complied with
à to Packaging packaging to use use CONDITIONNEMENT LEVEL 2 PACKAGING NIVEAU 2 2
s specific request On Renault ’specific request
LEVEL 3 PACKAGING Product with Level 1 or 2 packaging that does not resist to vertical compression or that Product with Level 1 or 2 packaging that is non -resistant to vertical compression does not allow a good stability on the pallet – Product whose storage quantity is limited to or which does not ensure good pallet stability 1 week of sales for high turnover reference or 1 month for the other references
Corrugated cardboard box Priority should be given to Galia standard
Product with Level 1 or 2 packaging that is non Product with Level 1 or 2 packaging that does resist to vertical compression or is load bearing
No level 3 packaging in general
LEVEL 4 PACKAGING
2.3
ProductProduct whose dimensions the dimensions match of which with standard adapt todimensions standard dimensions: (1,200 x 1,000; 800 x 600 and 1,200 x 800)
Standard pallet
’ With Renault approval
No -standard pallet n
Heavy product With Renault approval ’s approval
R -usable packaging e or -pallet box
Packaging level or ESN (Negociated Standards) Packaging consists of a maximum of 5 levels.
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Annexe 11 normative
Each level is defined by a type of packaging, identification, a quantity and a graphic. Level 1 unit or sales unit (SU) This is the primary packaging in which the product is sold to the final customer. It can be : - A unit packaging : a plastic bag for a hose - A grouping packaging for several parts : a sachet with 50 screws - A grouping packaging with different parts inside : a cardboard box with a Timing Belt Kit consisting of a tension roller, a guide roller and a belt. Level 2 unit or product grouping unit This is a homogenous grouping of N Level 1 units. This level relates solely to a specific Renault request and so may not be needed. This is the smallest grouping unit. Level 3 unit or overpack unit An overpack contains identical products and is mainly used by vendors or customers for in-house handling. It consists either of a grouping of several Level 2 units, or a grouping of several Level 1 units in case there is no Level 2. Its weight may not exceed 15 kg. This level may not be needed. The use of ODETTE containers is not permitted for parts and accessories. However, their implementation can be considered for certain flows for which the solution “Odette containers” is more economical. PL level unit or Pallet Layer When the part allows it, the PL level consists of one or several units of the lower level unit. These lower level units will form one or several layers on a wooden pallet or a grouping container. This level is used in order to reduce the restocking quantity while keeping the possibility to stack the goods. Level 4 unit or handling unit It is the highest grouping level. This packaging is used for transport and handling between the vendor and the customer. It must be graspable by a forklift, by the way the use of a pallet to bear the load is compulsory. Level 4 units generally contain several lower packaging units. In some cases (generally for large parts such as a body, engine, etc.), Level 1 and Level 4 are the same.
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Packaging levels
level 3
Multiple of levels 1 or 2 level 4
level 2
N SU level 1
1 SU
PL Level
Level 2
Level 3
N SU Level 1
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2.4
General packaging engineering
2.4.1
Product protection
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Annexe 11 normative
It’s the main function of the packaging and therefore it must ensure the product is adequately protected from the time it is packaged at the vendor's to its use by the final customer. Thus, the packaging must be designed to conserve all of the initial qualities of the product in their entirety throughout the supply chain, i.e. transport, storage and handling and even for return flow to DLPA. 2.4.2
Placing The product shall be placed in its packaging (unit box or palletized load) in compliance with the following rules :
2.4.3
Optimum packaging fill : no empty space more than 20% of the part volume and unit box dimensions must be as close as possible to those of the part. Galia cardboard boxes (or supplier standard cardboard boxes) will preferably be used before any upgrading
Easy placing and extraction of the product, without any risk of damage or any risk to the operators.
Maximum authorized weight Level 1 :
Over 15 kg, packaging must be designed to allow direct handling by a forklift.
Level 2 and 3 :
15 kg for packaging whose no dimension exceeds 1m.
10 kg for packaging whose at least one of its dimensions exceeds 1m.
Level 4 :
Pallets and box-pallets : 500 kg.
Renault reusable packaging : 600 kg.
Specific packaging for some product groups : more than 600 kg (see with Packaging Coordinator)
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2.4.4
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Ergonomics and security The packaging must be designed so as to avoid any risk for security or health for people that will have to handle it. Therefore, ergonomic constraints will be taken into account while designing the packaging such as handles or straps that allow an easier handling of heavy or large products. Any packaging that will show a risk for operators will be refused. Staples and metallic straps and are prohibited.
2.4.5
Quantity per level and coherence with delivery requests For Level 3, PL Level and level 4, parts quantity must match with 1 week sales for references with high turnover and 1 month sales for the other references. The delivery requests sent by the stock management department are multiples of level 1, 3, PL or 4. The palletized load or the handling unit generally consists of only one reference of product. It is possible to mix and proceed to a grouping if the ordered quantities for several references consist of several grouping of level 3 or several references of level 1. Each grouping unit is clearly identified by a Galia label (part number and quantity). A label with marking “MIXTE” is placed on the pallet and also a packing list with all the references (see Appendix 12). Cardboard boxes grouping the same references are placed together on the pallet.
2.4.6
Interior outfitting of packaging For some fragile, abrasive, specific products... internal blocking can be implemented to preserve the quality of the product and the packaging and to ensure their protection, especially when moving them. In all cases, these devices must get the packaging coordinator’s approval or must be made accordingly with the recommendations described in this standard or in the product groups' specifications.
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EB73.03.160 2.4.7
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Annexe 11 normative
Closing The closure system must contribute to the overall solidity of the packaging. It must prevent any whatsoever opening during handling of the packaging. Under no circumstances the reference label can be used as a closing device
For particularly heavy or fragile products, the use of plastic straps, whose characteristics are described in Section 5, «Environmental specifications,» is recommended. In this case, cardboard or plastic corners may be placed at the angles between the straps and the packaging as protection. In the case that box with flaps (called American box) is used, flaps must be closed by gluing or adhesive tape.
In the case of use of corrugated cardboard box, the packaging is preferably closed by a cap cover (maintaining of the lid with adhesive tape or snap) and plastic strapping.
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EB73.03.160 2.4.8
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Annexe 11 normative
Graphic markings relative to handling (c.f. Standard NF EN ISO 780) All marking must be written in English and French languages FRAGILE Symbol reference : ISO 7000, No. 0621. Meaning : The content of the packaging is fragile and as a result must be handled with care. Location : must be placed near the top right hand corner of the four vertical sides of the packaging. TOP Symbol reference : ISO 7000, No. 0623. Meaning : indicates the correct vertical position of the dispatch packaging. Location : must appear in the same location as the « fragile » sign. When both symbols are required, the « top » symbol must always be the closest to the corner.
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EB73.03.160 2.4.9
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Annexe 11 normative
Labeling Each level of packaging must be labeled:
Level 1 and 2 must be labeled with the RENAULT GROUP secured label
Level 3 and 4 must be labeled using a GALIA label. A Renault label may not be stuck on a Level 3 or 4 packaging under any circumstances.
Labels must always be placed on the top left hand corner, whatever the packaging is, and on the smallest side for the boxes.
A) Renault labels Content of the information area :
Each Level 1 packaging must be marked SU 1 meaning «a sales unit.» For Level 2 packaging, the number of sales units in the package must be indicated (N SU).
RENAULT 10-digit part number : This number must be clearly legible. This is why it is formally prohibited to use a stamp to print it.
«made in» : this indicates in English the country of origin of the packed product. «Made in CE» is not authorized for products manufactured in one of the European Union countries.
Any new supplier has to use the RENAULT GROUP secured label for its products. Refer to “RENAULT GROUP secured label” specifications EB73.08.100 in order to get all standards. Packaging dimensions must allow that labels are stuck flat. There are 2 label formats. So, it is important to order and use the good label size accordingly with packaging dimensions. B) Standard GALIA labels Level 3 and 4 These labels must comply with the specifications of the GALIA ETI 1 and GALIA ETI 9 standard. All fields in the label must be documented. GALIA label example : see Appendix 8 For Level 4, the GALIA label must be placed on the top left on the smallest side and close to the opening area, if relevant.
2.4.10
UV protection For light-sensitive products, the packaging must provide protection from UV rays to ensure quality and durability of the articles.
2.4.11
Anti-corrosion protection For products prone to corrosion, protection will be made with anti-corrosion products through steam diffusion (VCI : Volatile Corrosion Inhibitor) : sachets, film… The use of such packaging must be indicated by a special label as specified in Appendix 9, in order to warn the operators of the particular attention they must take. Under no circumstances oiled products can be placed directly into a cardboard box. They should be cleaned or placed beforehand in a sealed bag.
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EB73.03.160 2.4.12
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Protection against extreme temperatures If required, make sure that products sensitive to frost and/or high temperatures are adequately protected.
2.4.13
Dangerous substances Packaging and their labels must comply with current standards and must ensure the safety and health of operators and users. Non-compliance with this rule will result in the product's immediate removal from sale. Beside of this, IMDG standards must absolutely be respected during deliveries. Marking of products with Characteristics determining Safety and/or compliance with regulations (C.S.R) For products with Security Characteristics regulation (S.C.R), each level of packaging must show the following sign :
3
Main packaging product groups This section describes the main packaging groups used for RENAULT products noted in paragraph “Subject” of this standard and the technical characteristics that must be complied with.
3.1
Plastic bags and film
3.1.1
Bags Scope of use Use to protect products whose appearance is important and to pack small parts. Specifications Usual materials LDPE (Low Density PolyEthylene), PP (polypropylene). Dimensions of bags
The dimensions of the bags must be as close as possible to those of the product, while enabling a 50 X 70 mm label to be stuck flat. The product should go freely into the packaging without damaging it. Colour of the bags
Transparent. Opaque or UV-treated to provide protection from the sunlight for light-sensitive and textile products. Minimum thicknesses 100 µm, based on the weight and shape of the product. Closing
Thermo-weld compulsory, all other closing device is prohbited (staples, adhesive tape, minigrip, zip, label, etc.). Perforation
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Micro-perforated bags are preferable to minimize the space used in the boxes.
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EB73.03.160 3.1.2
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Annexe 11 normative
Films Scope of use Use plastic films to :
Cover parts (protection against dust....)
Protect a sensitive area of the part
Provide support for parts (a definition which is close to the use of spacers : film used as a cushion on a spacer for parts that are sensitive to abrasion from the cardboard)
Separate the parts
Maintain packaging accessories (e.g. : support windscreen protective elements). Usual materials LDPE (Low Density PolyEthylene), PP (polypropylene), cellular structure, («doufline», bullpack).
3.1.3 Covers Scope of use Covers are used to cover the whole palletized load :
To protect the contents from outside impacts (dust, water…)
To conserve the stability of the palletized load by their retractable nature. Usual materials LDPE (Low Density PolyEthylene), PP (polypropylene). To ensure the maintaining of the palletized load by the cover, it must be retracted below the palette.
3.1.4
Stretch wrapping Scope of use Use of a stretch wrapping film to wrap the palletized load in order to ensure the stability of the whole. Usual materials LDPE (Low Density PolyEthylene) To ensure the stability of the palletized load, it is compulsory for the stretch wrapping to be joined to one of the blocks on the pallet.
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Cardboard boxes and containers For corrugated cardboard packaging, the following must be printed on the box :
either a stamp indicating its classification, according to French Standard NF Q 12-008 for simple wall and double double wall corrugated cardboard, or according to French Standard NF Q 12-009 for triple wall corrugated cardboard, the year of manufacture and the brand of the lab that carried out the quality control tests
Or another marking approved by DIL packaging department. Each time it is possible, the dimensions of cardboard packaging must comply with the GALIA standard (c.f. Appendix 1). They are used to protect fragile products from shocks and squashing or to group a certain quantity of sales unit. We recommend the use of compact or corrugated cardboard / from micro mini to great fluting / from single to triple fluting.
4
Transport and handling packaging (level 4) It must be possible to use forklifts to grasp this Level 4 packaging. The various types of packaging are :
4.1
Standard Renault re-usable packaging
Standard pallets
Non-standard and non-reusable pallets
Box-pallets.
Standard Renault re-usable packaging The specimen used for parts and accessories are : SLI 760, SLI 1200 and SLI 2000, with exclusion of all other standard packaging used for mass production. Conditions of use They are dedicated to packaging of heavy or aggressive parts according with rotation conditions. Sensitive parts : Place a cardboard protection around the re-usable packaging. Placing
The parts may not exceed the height of the grids.
When the containers are self-stackable for transport, they may not be placed upside down (the openings of the containers must all be on the same side). Re-usable packaging is not accepted at ST OUEN CDPR. How to get SLI Contact standard packaging management at the following address «
[email protected]»
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Specifications
SLI 0760 Tare
118 kg
Charge utile
600 kg
Longueur H.T
1200 mm
Largeur H.T.
1000 mm
Hauteur H. T.
930 mm
Gerbage
5/1
SLI 1200 Tare
150 kg
Charge utile
600 kg
Longueur H.T
1600 mm
Largeur H.T.
1200 mm
Hauteur H. T.
930 mm
Gerbage
5/1
SLI 2000 Tare
281 kg
Charge utile
600 kg
Longueur H.T
2400 mm
Largeur H.T.
1200 mm
Hauteur H. T.
975 mm
Gerbage
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4.2
Pallets
4.2.1
Palletization
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Annexe 11 normative
All deliveries must be palletized. The load must be distributed over the full surface of the pallet. Over-sized or under-sized load is prohibited. Because of pallet stacking, these specifications are essential.
All palletized loads must remain in position on the pallet until the point of use by the final customer.
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Particular attention must be paid to stabilizing heavy loads. In no circumstances may Level 1 packaging be placed directly on pallets. It is compulsory to place a cardboard spacer between the pallet and the products. In addition, the top side of the palletized load must be protected to allow stacking and storage.
Maximum and optimum height of the palletized load : 1150 mm including the pallet except for parts to be delivered to Villeroy CDPR where max authorized height is 1250 mm (see Packaging Coordinator for validation) Maximum weight of the palletized load : 500kg. Storage method : The quality of the packaging materials used must enable stacking
1 / 1, dynamic conditions
3 / 1, static conditions with a total weight onto the below pallet that cannot exceed 1 ton. The heaviest palletized load always must be at the lower level of the pile. See Appendix 2 for palletizing of standard GALIA cardboard packaging.
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EB73.03.160 4.2.2
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Annexe 11 normative
Standard pallets
4.2.2.1 Non-reusable standard GALIA pallets A. 1200 x 1000 non-reusable pallet – Payload < 1000 Kg – 5 soles – 4 inputs
This pallet is the one to use in priority. Other pallets described in this documents, as well as the standard GALIA 1200 x 1000 pallet - 3 soles - Payload < 600 Kg, may only be used with the prior approval of the Packaging Coordinator. Dimensions and tolerances Part number
Constituent parts (1)
Quantity
Dimensions in mm Length
Width
Thickness
1
Upper board
6
1,200
100 (-0)
15 (-0)
2
Crossbar
3
1,000
90
15 (-0)
3
Lower board
5
1,000
100
15 (-0)
4
Die
3
90
80
100
5
Die
6
110
80
100
(1) C.f. diagram below
Wood: Choice of species Quality So-called «standard» quality Wedging: on : smooth points, 2.5 x 40 - on -: twisted points, 3.2 x 70 ( per join) - on -: twisted points, 3.2 x 70 ( per join) Dies: perpendicular to the thread
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B. 800 x 600 non-reusable pallet - Payload < 400 Kg - 3 soles Dimensions and tolerances Part number
Constituent parts Quantity (1)
Dimensions in mm Length
Width
Thickness
1
Floor
5
800
80 (-0)
15 (-0)
2
Upper crossbar
3
600
80 (-0)
18 (-0)
3
Die
6
80
80
100
4
Lower crossbar
3
600
80 (-0)
18 (-0)
(1) C.f. diagram below
Wood: Choice of species Quality : So-called «standard» quality Wedging: on : smooth points, 2.5 x 40 ( per joint) - on : twisted points, 3.2 x 70 ( per join) on : twisted points, 3.2 x 70 ( per join) Dies: perpendicular to the thread
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4.2.2.2 European pallet 800 x 1200 pallet - Payload < 600 Kg - 4 ways Pallets in compliance with the EUR standard are permitted but may not be recovered by the vendor. Dimensions and tolerances (according to Standard EN 13698-1) Part number
Constituent parts (1)
Quantity
Dimensions for a water content of 22% in mm Length
Width
Thickness
1
Lip platform
2
1,200 ± 3
100 ± 3
22 + 2/0
2
Lip border
2
1,200 ± 3
145 +5/-3
22 + 2/0
3
Centre platform
1
1,200 ± 3
145 +5/-3
22 + 2/0
4
Crossbar
3
800 ± 3
145 + 5/-3
22 + 2/0
5
Central border
1
1,200 ± 3
145 + 5/-3
22 + 2/0
6
Intermediate border
2
1,200 ± 3
100 ± 3
22 + 2/0
7
Outside die
6
145 +5/-3
100 ± 3
78 + 1/0
8
Centre die
3
145 +5/-3
145 + 5/-3
78 + 1/0
(1) C.f. diagram below
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EB73.03.160 4.2.3
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Annexe 11 normative
Non-standard and non-reusable pallets All products whose dimensions are greater than standard pallets must be palletized in compliance with the following principles :
: dies: 110 x 80 x 90 - Qty: 8 : dies 80 x 80 x 90 - Qty : 2 : upper boards 100 x 15 : 100 x 15 soles
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A : Length : 1800 maxi* B : Pallet width 1200 maxi* - preferably 1150 C : space between boards - 300 mm max * If the product dimensions allow
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4.3
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Box-pallets As a general rule, the specifications are the same to those for the cardboard boxes and pallets. It must be easy and quick to separate the cardboard from the pallet. However, the unit must be maintained so that the cardboard does not slip off the pallet.
Provide side openings that can be folded back at the level of the smaller sides to facilitate handling.
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EB73.03.160
5
Environmental specifications
5.1
General
5.1.1
Ensuring the compliance of packaging
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All packaging and packaging elements used by Renault vendors must comply with European Directive No. 94/62/CE «Packaging and packaging waste» transcribed into French Law by Decree No. 98/638 of July 20, 1998 relative to the incorporation of environmental requirements in the design and manufacture of packaging. To comply with environment standards and also integrate recycling aspect, the weight of each material used for the packaging must be declared. That is the reason why it will be noted in the Packaging Proposal Sheet.
5.1.2
Composition of packaging Packaging must be made of a single material. When this is not possible, vendors should seek to limit the diversity of materials used and to ensure that these materials are used in such a way as to be easily separated at the end of the packaging life.
5.1.3
Marking Scope : All materials used for packaging, including wedging, closing and labelling elements (within the limits of technological and economic conditions at that time. Marking costs must not be excessive in relation to the cost of the packaging itself). Goal : Facilitate collection, re-use and recycling. Position of the marking :
The marking must be on the packaging itself. If not possible, it should be on a label stuck on the packaging.
The marking must be clearly visible and easily legible.
The marking must have an appropriate life span, including when the packaging is open.
Symbol to use : in accordance with standard ISO 14021, If a symbol is used to declare recycled or recyclable contents, this symbol must be the Möbius loop. This symbol must comply with the graphic requirements of ISO 7000, symbol No. 1135.
Examples of Möbius loops
If this symbol is used to declare recycled content, it must include the percentage of recycled material. © RENAULT 2001
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Examples of acceptable location of percentage If this symbol is used, it can include the identification of the material. Materials identification system :
In accordance with Directive No. 97/129/CE, the numbering system to be used is the one provided in Appendix 10.
Abbreviations for the material(s) used may also be used for the identification (see Appendix 10). Example : HDPE = High Density PolyEthylene.
Materials may also be identified using the numbering and/or abbreviation system. These identification methods must appear in the centre or below the graphic marking indicating the recyclable nature of the packaging.
Recyclable plastic product : Use of the DIN 6120-1 and DIN 6120-2 symbols or the Möbius loop.
For example, for packaging or wedging elements made from High Density PolyEthylene that may be recycled :
or
HDPE
HDPE
Heavy metals According to Article 11 of Directive No. 94/62/CE, the sum of the concentration levels of :
Lead,
Cadmium,
Mercury,
Hexavalent Chrome, present in the packaging or its elements may not exceed 100 ppm (parts per million) in weight (i.e. 100 mg per kg).
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5.2
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Special rules Cardboard As much as possible, it should be designed using the maximum of secondary recycled materials. Wood Products used to treat the raw material must be compatible with environmental standards in force. In accordance with the requirements of Directive No. 96/59/CE, it is prohibited to use wood elements treated with products that include
PCB (polychlorobiphenyles)
PCT (polychloroterphenyles) Metal may be included only for nailing and stapling. The use of mixed wood-cardboard packaging is authorized insofar both components can easily be separated. Plastics Mixing of plastics that would inhibit recycling are prohibited. A table summarizing the compatibility of the various plastic materials is given in Appendix 11. As far as possible, select plastics from the same family or compatible families for the individual parts of the same packaging in order not to obstruct the recyclable nature of the packaging. Inks and paints Use inks and paints that do not prevent the recycling of the main constituent parts of the packaging, in compliance with legislation in terms of concentrations of heavy metals. Labels The type of label and the sticking method to the packaging may not prevent the recycling of the material to which the label is stuck. Adhesive tape The use of adhesive tape must be limited to the strict requirement, as the package becomes a composite when tape is stuck to it. Adhesive tapes may not prevent the recycling of the materials on which they are placed. Glues All glues used must be biodegradable and therefore may not obstruct the recycling process, either by their composition or the quantities used. Banding Use thermo-welded plastic ties for banding or ties with a closure system that is the same as the ties themselves (homogenous materials). Metal for banding and closure systems are formally prohibited. Wedges All fittings fixed to the packaging are included in the packaging recycling process. For wedges
their use must be kept to the strict minimum required to ensure the quality of the product. It must be easy to separate them from the rest of the packaging.
Very volatile wedges (such as chips, synthetic straw, paper fibres…) are prohibited.
The use of expanded polystyrene (PSE) should be limited. As for cellular products produced from chlorinated or fluorinated hydrocarbons (such as CFC and HCFC), they are prohibited. Nailing and stapling The quantity of nails must be kept to the strict minimum required. Staples are prohibited. Preference must be given to gluing and banding.
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Useful addresses GALIA (Group for the Improvement of Liaison in the Automobile Industry) 96, avenue du Général Leclerc 92514 Boulogne-Billancourt Cedex www.galia.com Laboratoire National d’Essais (LNE) Centre Logistics et Emballage Z.A. de Trappes-Elancourt 29, avenue Roger Hennequin 78197 Trappes Cedex www.lne.fr AFNOR (French Standardisation Authority) 11, avenue Francis de Pressensé 93571 Saint-Denis La plaine Cedex www.afnor.fr
7
List of referred documents NOTE
:
For undated documents, the latest version in force applies
Décret n° 98/638 :
Decree relating to the incorporation of environmental requirements in the design and manufacture of packaging Directive n° 94/62/CE : Directive relating to packaging and packaging waste Directive n° 96/59/CE : Directive relating to elimination of PCB (polychlorobiphenyles) and PCT (polychloroterphenyles) Directive n° 97/129/CE : Decision by the Commission dated 28 january 1997 establishing the identification system for packaging materials, in accordance with 94/62/CE European Parliament directive relating to packaging and packaging waste ISO 780 : Packaging - Pictorial marking for handling of goods ISO 7000 : Graphical symbols for use on equipment; index and synopsis ISO 14021 : Environmental marking and declarations - Self-declared environmental claims (Type II labeling) DIN 6120-1 : Marking of packaging and packaging materials for recycling purposes - Plastics packaging and packaging materials - Part 1: Graphical symbols DIN 6120-2 Marking of packaging and packaging materials for recycling purposes - Plastics packaging and packaging materials - Part 2: Additional marking EN 13698-1 : Specifications of products for pallets – Part 1 : manufacturing specifications for wooden pallets ; 800 mm x 1200 mm NF Q 12-008 : Paper and cardboard. Corrugated cardboard. Characteristics of single wall and double wall corrugated cardboard for packaging NF Q 12-009 : Paper and cardboard. Corrugated cardboard. Characteristics of triple wall corrugated cardboard for packaging. EB73.08.100 : RENAULT GROUP's secured label for marking of spare parts and accessories, and their packaging GALIA EMB.1 : Cardboards and pallets non-returnable GALIA ETI.1 : Barcode labels
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Appendix 1 : Dimensions of non-reusable packaging, according to the GALIA standard These documents are extracted from GALIA standard EMB.1. UNIT PACKAGING (handling and packaging units) Outside packaging Approx. dimensions Inside Volume
C1A C1B C1C C2A C2B C2C C2D C2E C2F
1200+1000+1000 1200+1000+1000 1200+1000+1000 1200+1000+600 1200+1000+600 1200+1000+600 1200+1000+750 1200+1000+750 1200+1000+750
17 3 3A 4 5 5A 6 7 7A 8 8A 9A 9 10 11 11A 12 12A 13 13A 14 15 15A 16
1200+330+187 1200+500+500 1200+500+375 1200+500+300 1000+600+500 1000+600+375 1000+600+300 1000+400+500 1000+400+375 1000+400+300 1000+400+187 600+400+375 600+400+300 600+400+250 600+400+200 600+400+187 400+300+300 400+300+250 400+300+200 400+300+187 400+300+150 300+200+200 300+200+187 300+200+125
C40 C41
300+200+90 300+200+50
© RENAULT 2001
Category of corrugated cardboard
Load contained RCV (kg) (daN)
Ref. L+W+H (mm)
Max
1/2 box
1/2 box + sleeve
Cover
(dm3)
1100 200 1100 400 1100 800 670 120 670 200 670 800 840 120 840 250 840 800 A = American 60 10 280 10 210 10 170 10 280 15 210 15 170 15 190 15 140 15 110 15 70 15 80 15 65 15 55 15 44 15 40 15 32 15 26 15 21 15 20 15 16 15 10 15 9 15 6 15 4 2
20 20
800 2.7 or 2.R 1600 3.01 (2.7 + 2.3) or (2.R + 2.N) 2000 3.01 + 2.7 or 2.R 930 2.7 or 2.R 1600 3.01 (2.7 + 2.3) or (2.R + 2.N) 2400 3.01 + 2.7 or 2.R 930 2.7 or 2.R 1600 3.01 (2.7 + 2.3) or (2.R + 2.N) 2400 3.01 + 2.7 or 2.R C = Bubble cap cover 450 2.2 or 2.N 480 " 480 " 510 " 480 " 480 " 510 " 350 " 400 " 430 " 430 " 350 " 420 " 490 " 510 " 510 " 380 " 380 " 380 " 380 " 380 2.2 or 2.N 190 1.3 or 1.E 190 1.3 or 1.E 190 1.3 or 1.E 190 190
1.3 1.3
Source : PEGI Renault
2.4 " " " " " " " 2.4 1.1 " " " " " " " " " " " " " " " " " " " " " " " 1.1 1.1
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The tolerances for the dimensions are the standard tolerances in the trade : For packaging whose length is 600 mm : on length and width : + 0 - 10 mm on height : + / - 3 mm For classes 9 and 10, the RCV values are calculated for use with a GALIA 5-sole-pallet. In case of use on GALIA 3-sole-pallet, (which requires agreement between the parties), these RCV values must significantly be higher (30 - 40%). To avoid selecting the corresponding cardboard class, it is better to place a rigid layer (2.2 cardboard) on top of the palettized load, under the pallet cover, covering the whole surface.
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Appendix 2 : palletization of non-reusable packaging in GALIA standard cardboard boxes Outside Dimensions
Max load Ref. of the packaging contained L+W+H (kg) (mm)
C1A C1B C1C C2A C2B C2C C2D C2E C2F 17 3 3A 4 5 5A 6 7 7A 8 8A 9A 9 10 11 11A 12 12A 13 13A 14 15 15A 16 C40 C41
1200+1000+1000 200 1200+1000+1000 400 1200+1000+1000 800 1200+1000+600 120 1200+1000+600 200 1200+1000+600 800 1200+1000+750 120 1200+1000+750 250 1200+1000+750 800 A = American 1200+330+187 10 1200+500+500 10 1200+500+375 10 1200+500+300 10 1000+600+500 15 1000+600+375 15 1000+600+300 15 1000+400+500 15 1000+400+375 15 1000+400+300 15 1000+400+187 15 600+400+375 15 600+400+300 15 600+400+250 15 600+400+200 15 600+400+187 15 400+300+300 15 400+300+250 15 400+300+200 15 400+300+187 15 400+300+150 15 300+200+200 15 300+200+187 15 300+200+125 15 300+200+90 300+200+50 (*) 3-platform pallet
© RENAULT 2001
1200 x 1000 PALETTE 800 x 600 PALETTE Palletized load Palletized load Palletized load height height height 1150 mm max 900 mm max 900 mm max Max No. of Max Max No. of Max Max No. of Max Palletize pkg No. of palletise pkg No. of palletise pkg No. of d Weight per beds d per beds d Weight per beds (kg) bed Weight bed (kg) bed (kg) 200 400 800 120 120 200 1 1 200 800 800 1 1 120 120 250 250 800 800 C = Bubble cap cover 180 3 5 120 3 4 40 2 20 1 60 2 2 40 2 2 80 3 40 2 60 2 30 1 90 2 2 60 2 2 120 3 60 2 90 2 45 1 135 2 90 3 2 180 3 3 90 2 270 5 180 4 225 2 150 2 60 2 300 3 150 2 60 2 300 5 4 225 5 3 90 2 3 450 5 225 3 90 3 450 5 300 4 120 4 600 3 300 2 120 2 600 4 450 3 180 3 900/600 10 5/4* 450 10 3 180 4 3 900/600 5/4* 600 4 240 4 900/600 6/4* 750/600 5/4* 300 5 900/600 20 3/2* 900/600 20 3/2* 360 8 3 900/600 3/2* 900/600 3/2* 360 3 900/600 3/2* 900/600 3/2* 360 3
20 800/400 20 800/400
20 20
2/1* 2/1*
800/400 800/400
Source : PEGI Renault
20 20
2/1* 2/1*
320 320
8 8
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Appendix 3 : Invoicing of sorting and touch-ups of packaging Renault DLPA has to «sort and touch-up» packaging when products are delivered in packaging that does not comply with specifications (the standard negotiated conditions), without packaging, when the label is either incorrect or missing, or when the packaging proposal has not been validated. Without any prior derogation to the standards, our «Quality» department attributes the anomaly to the supplier and the dispute notice results to an invoice raised by «Accounts.» The invoice includes :
direct labour costs, at the current rate
the cost of materials used (bags, labels, plastic film…)
a fix administrative fee of € 150.00 per delivery note
Some explanations about non-compliance treatment in reception area and about dispute notes Non-compliance treatment The operator notes the non-compliance (a packaging defect from supplier) He fills in the relevant data in the incident analysis sheet (supplier’s name, supplier’s code, detected anomaly…) Then he sorts out the defect products, identifies (by isolating from the rest of the delivery) the noncompliant delivery, brings the defect products with the corresponding documents to the dedicated area, and finally proceeds to the analysis of the defect : he indicates the corrective actions (repacking, return…) He checks whether any derogation or an authorization was issued, and makes the decision regarding the non-compliance corrective treatment. He issues a dispute note (sorting or touch-ups of packaging) and afterwards, defect parts are either sent back to the supplier or brought back into conformity by the quality department operator Dispute note : On the incident analysis sheet, the quality department operator ticks the option touch-up with invoicing and notes the appropriate "touch-up" number. He fills the touch-up note with data noted in the incident sheet and clearly indicates the job to be done. Then, the packaging department remits in compliance the defect parts. Time spent to this operation is then noted in the touch-up sheet, the material used and its costs and also the date of work. The quality department operator sends the sheets as follow : White sheet to the supplier, Pink and yellow sheets to the account department, The green sheet is kept into the appropriate supplier file of the Supplier Quality service
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Appendix 4 : Derogation Direction Logistique Pièces Accessoires Direction Ingénierie Logistique Pièces & Accessoires Parc d'Activités des Bellevues - Avenue du Gros-Chêne 95610 Eragny sur Oise
Téléphone : (+33)1.76.84.04.04 Internet : www.renault.fr
Dérogation n°..
Date :
From :
CPC
Phone :
00 33 1 76 8
To :
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
COMPANY / COFOR: COPY:
[email protected]
Subject : Derogation for the delivery of products whose packaging is not compliant with DIL C&E specifications Reference(s) concerned :
Issue :
Absence of RENAULT GROUP secured label,
Absence of RENAULT GROUP graphics,
Cardboard supplier failure,
Flow troubleshooting
Other, to specify : …..
Parts quantity : Delivery date / Date of expiry of the derogation:
ADMINITRATIVE FEE APPLIED :
OUI
NON
REPACKING COSTS INVOICING :
OUI
NON
This derogation is exceptional, any all other non-compliant deliveries will lead to the return of the parts or demerite points with remittance into conformity at your costs (material, labour and penalty fees). Remaining at your entire disposal for any further information Daniel MAINGUY Signature électronique
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Appendix 5 : Packaging Proposal Sheet Return document to : Fax : 01 76 89 12 60 RENAULT Parts and Accessories Logistics Division B.P. n°6 F-95611 Cergy Pontoise Cedex M:
PACKAGING PROPOSAL
Purchasing manager :
VENDOR DETAILS Date : Vendor name : Account No. : Place of production :
Address : Contact : Telephone : Fax :
PRODUCT DETAILS Spare parts Vendor Reference: RENAULT reference: Description :
Accessories
Motrio parts Standard exchange parts Dimensions (L w h) in mm: Unit weight (g): Vehicle or part:
Level
Proposed packaging Outside dim in mm (L x w x h)
Level 1
Bulk
Sales unit
RENAULT label
Unit packaging price (1) = (2)*(3)
Quantity per Packaging packaging (2) price per part (3)
Type of Weight DLC time / part (6) materials of material s
RENAULT safety label RENAULT/NISSAN label Cardboard box with RENAULT graphic Neutral cardboard box
(SU1)
Plastic bag Other (specify) RENAULT label
Level 2
Grouping (on request by RENAULT)
RENAULT safety label RENAULT/NISSAN label Plastic bag Neutral cardboard box Other (specify)
Level 3
Standard Galia box
Overpack
Special box Galia label Other (specify)
Level 4
Palletized load
Handling
Returnable packaging unit Galia label Other (specify)
Hourly direct labour cost rate (DLC) Total DCL time per part (5) = sum (6) applied (4) (4) :
Total packaging cost : Materials (sum 3)
Vendor’s stamp :
Department stamp DLPA packaging :
Labour (4)*(5) Transport
Date :
Total cost
Date :
Le : FAILURE to comply with the information above will give rise to a VENDOR QUALITY INCIDENT PROCEDURE
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Appendix 6 : Packaging proposal documentation
Return document to :
PACKAGING PROPOSAL
Fax : 01 76 89 12 60
RENAULT Parts and Accessories Logistics Division PO Box 6 F-95611 Cergy Pontoise Cedex Mr. : Purchasing manager :
Dept: 01382 Dept:
Packaging technician's name and department
Reminder of RENAULT purchaser name and department
VENDOR DETAILS Date :
Address :
Vendor name :
Contact :
Account No. :
Telephone :
Place of production :
Fax :
Vendor identification
PRODUCT DETAILS Spare parts
Accessories
Motrio parts
Standard exchange parts
Vendor Reference :
Dimensions (L w h) in mm :
RENAULT reference :
Unit weight (g) :
Designation :
Vehicle or part :
Product identification
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EB73.03.160 Level :
Proposed packaging
Level 1
Bulk
Sales unit
RENAULT label
(SU1)
Outside dim in mmUnit (L x l x h) packaging price (1) = (2)*(3)
Quantity per packaging (2)
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Packaging price per part (3)
Annexe 11 normative Type of Weight of materials materials
DLC time / part (6)
RENAULT safety label RENAULT/NISSAN label Cardboard box with RENAULT graphic Neutral cardboard box Plastic bag Other (specify)
Level 2
RENAULT label RENAULT safety label
Grouping (on request
RENAULT/NISSAN label
by RENAULT)
Plastic bag Neutral cardboard box Other (specify)
Level 3
Standard Galia box
Overpack
Special box Galia label Other (specify)
Level 4
Palletized load
Handling
returnable packaging unit Galia label Other (specify)
Outside dimensions of the packaging for each level (Length x width x height). This is very important for controlling volumes and allocating crates in our stores. Unit cost of each component of the packaging Quantity of parts per packaging Each level used must be documented. Unit cost of each packaging component, divided by the quantity of parts in the corresponding level. This is vital for dealings with purchasing. Type of materials the packaging is made of. E.g.: cardboard, polyethylene, wood, etc.
Weight of materials used for the packaging only
Labour time invoiced per packaging level, divided by the quantity of parts.
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EB73.03.160 Hourly direct labour cost rate (DLC) Total DCL time per part (5) = sum (6) applied (4) (4) :
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Total packaging cost : Materials (sum 3)
Vendor’s stamp :
Department stamp DLPA packaging :
Labour (4)*(5) Transport
Date :
Total cost
Date : Le :
FAILURE to comply with the information below will give rise to a VENDOR QUALITY INCIDENT PROCEDURE Total labour hours for packaging Hourly labour rate invoiced. Total packaging costs for a part (excluding the part price).
Approval by the RENAULT Parts and Accessories Logistics Engineering Division packaging department
Notice concerning the management of disputes
Vendor commitment area. Date and signature compulsory
It is vital that vendors provide complete documentation for the packaging proposal. Failure to do so will result in non-approval by our departments. Furthermore, it is desirable to include all additional documents enabling approval by our departments: palletization plan, photo, packaging process, etc.
Appendix 7 : List of available product group recommendations TITLE © RENAULT 2001
Technical product group Source : PEGI Renault
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Wings Airbags and pretensioners Shock absorbers Fog light Hitches Door protection moulding Battery and Battery chart Roof bars Engine cradles Gearboxes Bumpers Spark plugs Glow plugs Wiring White body Bonnets Roof boxes Body sides Belts Brake discs Exhausts Axles Rear lights Filters Drums Roof racks Roof linings Aluminium rims Steel rims Over-moulded rear windows Engines Rear doors Side panels Windscreens and rear windows Roofs Brake pads Side doors Headlamps Side windows
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number 200 711 820 818 911 341 631 914 147 061/092/100/101 282/284 601 532 --212 201 710 217 503/507 114 033/034/035/060 118 633 520/554/501/513 --707 379/593 475 801 --008/040 203/208 223 851/854/864 224 803 202 632 852/853/855/856/857/858
Appendix 8 : GALIA label sample
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Labels comply with GALIA ETI 1 standards
Appendix 9 : VCI Anti-corrosion protection label sample
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A label following the general principles of the label below may be affixed on the packaging treated with VCI anti-corrosion protection to alert operators handling the packaging of the precautions to take.
Appendix 10 : Numbering and abbreviation system Materials Polyethylene terephtalate High-density polyethylene © RENAULT 2001
Source : PEGI Renault
Abbreviations
Numbering
PET HDPE
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Polyvinyl chloride Low-density polyethylene Polypropylene Polystyrene
PVC LDPE PP PS
3 4 5 6
Corrugated cardboard Non-corrugated cardboard Paper
PAP PAP PAP
20 21 22
Steel Aluminium
FE ALU
40 41
Wood Cork
FOR FOR
50 51
Cotton Jute
TEX TEX
60 61
GL GL GL
70 71 72
Paper and cardboard / miscellaneous metals Paper and cardboard / plastic Paper and cardboard / aluminium Paper and cardboard / white iron Paper and cardboard / plastic / aluminium Paper and cardboard / plastic / aluminium / white iron
* * * * * *
80 81 82 83 84 85
Plastic / aluminium Plastic / white iron Plastic / miscellaneous metals
* * *
90 91 92
Glass / plastic Glass / aluminium Glass / white iron Glass / miscellaneous metals * C plus abbreviation for the predominant material (C/)
* * * *
95 96 97 98
Colourless glass Green glass Brown glass
Appendix 11 : Compatibility of plastics Mix material ABS ABS
PC
PMMA
PS
PVC
SAN
PA
PBT
PE
PET
POM
PP
3
3
2
2
3
0
1
0
1
1
0
3
0
1
3
0
3
0
3
0
0
1
3
3
0
0
0
0
1
0
0
2
1
0
0
1
0
0
PC
3
PMMA
3
3
PS
2
0
Matrix © RENAULT 2001
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material PVC
2
1
3
0
3
0
0
0
0
0
0
SAN
3
3
3
2
3
PA
0
0
0
1
0
0
0
0
0
0
0
0
1
0
1
0
PBT
1
3
0
0
0
0
1
0
0
0
0
PE
0
0
0
0
0
0
0
0
0
0
0
3
0
0
PET
1
3
0
1
0
0
1
0
0
POM
1
0
1
0
0
0
0
0
0
0
PP
0
0
0
0
0
0
0
0
1
0
0 0
3 : compatible 2 : limited compatibility 1 : compatibility in small quantities 0 : incompatible
ABS PC PMMA PS PVC SAN PA PBT PE PET POM PP
Acrylonitrile butadiene styrene Polycarbonate Polymethylmethacrylate Polystyrene Polyvinyl chloride Styrene acrylonitrile Polyamide Polybutylen terephtalate Polyethylene Polyethylene terephtalate Polyoxymethylene Polypropylene
Appendix 12 : example of a mix packing list
7711259963 © RENAULT 2001
:
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8200549635
:
6 SU
8200864894
:
8 SU
7701782444
:
3 SU
7711555698
:
9 SU
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