Daimlerchrysler Insert Program Name

Daimlerchrysler Insert Program Name

Chrysler Construction Standards

AME – PT Plants

Revision Date: 11/12/07

SECTION 15990 – DUNNAGE AND CONTAINERIZATION

1,1REFERENCE

1.2QUALITY ASSURANCE & QUALITY CONTROL

1.3SCOPE

1.4QUOTATION

1.5TIMING SCHEDULE

1.6APPROVAL DRAWING SUBMITTALS

1.7DELIVERABLES

1.8GENERAL SPECIFICATION

1.9DESIGN

1.10 ERGONOMIC STANDARDS

1.11 PROTOTYPE & SAMPLE CONTAINERS

1.12PRODUCTION TOOLING

1.13 PRODUCTION BUILD

1.14TRANSPORTATION AND DELIVERY

1.15FACTORY PAINTING

1.16SUGGESTED SUPPLIERS

1.1 REFERENCE

  1. Related Sections: The following Sections contain requirements that relate to this Section:

Section 05500:(Metal Fabrications)

Section 09910:(Painting)

Section 15980: (PT Total Maintenance Spare Parts List)

Section 15195: (Material Handling Systems)

ETI – 103: Supplier Regulated Substance Certification Report. (

  1. Standards referenced in this Section:

American Society for Testing and Materials (ASTM) Standard

A 3696, Specification for Carbon Structural Steel

Corporate Material Handling Specifications:

(

1.2 QUALITY ASSURANCE & QUALITY CONTROL

  1. Supplier acceptance of a purchase order shall constitute acceptance of all assumed responsibilities associated withthe design, engineering, labor, material, fabrication, testing and installation supervision required to provide a complete and functional container and/or rack system to the satisfaction of the Chrysler Material Teamand in accordance with all applicable Chrysler and government standards.
  2. The container quotation submitted to the Chrysler purchasing department must incorporate all pricing necessary to meet, at a minimum, the requirements of these specifications. Compliance with these specifications shall not relieve the supplier of the obligation to provide a functional container system. The Owner will not be responsible for the accuracy of the specifications as they relate to the satisfactory performance of the total system.
  3. All submitted quotations must state that the equipment being quoted will be designed and built to this specification. Any deviation from these standards shall be clearly defined as such in the quotation. Under no circumstances will specifications be relaxed that compromise the purpose and intent of the process, safety of the employee or quality of the product. All deviations, additions, and/or deletions indicated in supplier quotations or information obtained through other persons or sources, without the expressed consent of the responsible plant engineer, will not be honored.

1.3 SCOPE

  1. To protect all part features/surfaces, determined to be critical to the quality of the part,from damage and debris during transportation, handling and storage.
  2. To develop a functional and flexible container and material delivery system that corresponds with the lean manufacturing philosophy and guiding principles.
  3. To design all Chryslerinternal containers in adherence to all applicable safety standards and per the Chrysler Ergonomics Do’s and Don’ts. See section 1.9 of this specification.

1.4 QUOTATION

  1. Suppliers shall quote the complete design and production of containers for the Chrysler Powertrain facility internal container system per Chrysler specifications. Each proposalmust include the recommended material type, gauge, tolerances, delivery and all other pertinent information. In addition, the quotation should be presented in such a manner that it is easily understood by any individual and/or department who may be required to review it.
  2. Pricebreakdowns must be provided for:

1)Design

2)Prototype

3)Tooling

4)Production cost per piece. This cost must incorporate all associated labor, material and equipment costs per piece.

5)Quote hot stamping or labeling application separately per container.

  1. Failure to conform to the general quotation pricing requirements, timeline schedule, specifications or quotation form may result in disqualification.
  2. Concept drawings showing general container concept, size, part quantity and orientation shall be submitted with eachsupplier quotation.
  3. Supplier initiated packaging or cost improvements are encouraged, but must be reviewed and approved by the program’s Material Team to ensure that the plants’ productivity is not adversely affected. Pricing for all options should be submittedalong with the original quote.
  4. Suppliers of automatic load/unload systems must furnish all dunnage utilized for their systems. No exceptions will be allowed.

1.5 TIMING SCHEDULE

  1. A Microsoft Project timeline, highlighting program milestones,must be submitted with the supplier’s quotation. It is the supplier’s responsibility to maintain the timeline progress report throughout the program and submit a copy, via fax or email, to Chrysler Plant Engineering upon request.
  2. Chrysler Plant Engineering shall approve each program phase (e.g., design, tooling and fabrication).
  3. Where automatic load/unload automation is provided, the automation supplier must also approve each container program phase.
  4. Allprogram timing delaysrequire an immediate corrective action plan. The CAP shall detail all steps necessary to meet the original target date.

1.6 APPROVAL DRAWING SUBMITTALS

  1. All drawings must adhere to the Chrysler CAD Standards and Drawing Numbering System.Refer to the following website for the CAD Standards and Specifications in their entirety:

(Supporting Document File Name and AMEPT Machine CAD Specifications)

  1. Approval drawing shall be submitted on a Chrysler title block and identify, at a minimum,the number of parts per container/tray, number of containers/trays per pallet, total pack load, part orientation, container dimensions, weight per tray and total weight per stack (both empty and loaded), color, Chrysler part number and description, container material and tolerances. Drawing shall also depict the part in the container in 3-dimensional views.
  2. Approval of drawings, prototypes, tooling and/or any individual production sampling by Chrysler Engineering does not relieve the supplier of their obligation to provide a functional system or fulfilling other program requirements. NOTE: Where automatic load/unload automation is purchased, the automation supplier must approve the container drawings prior to Chrysler submittal.

1.7 DELIVERABLES

A. Drawings & Manuals: within four (4) weeks of receiving a purchase order, the OEM shall submit one (1) hard copy and one (1) electronic set of prints to AMEPT engineer for Chrysler’s approval. With shipment, the OEM shall supply and ship one (1) set of paper copy drawings with Dunnage or Container and one CD of drawings and usage manuals to the responsible AMEPT engineer. Once Dunnage or Containers are qualified, the OEM shall update and ship three (3) paper sets of drawings and usage manuals to the plant representative as directed by the responsible AMEPT engineer. The OEM also supplies a signed copy of the Letter of Transmittal and a CD containing all “as Built” drawings of the equipment, manuals and scanned electronic copy of all individual component specification (“cut”) sheets and all spare parts lists the responsible AMEPT engineer.

(refer to web site

1.8 GENERAL SPECIFICATION

  1. Molded containers shall contain the following features. These same features must be painted or tagged on the side and bottomof non-molded type containers, unless otherwise instructed.

1)Chrysler NPM code

2)Property of Chrysler Powertrain facility and code, Chrysler logo with Chrysler part #. Lettering shall be 1" in height. (Visible from the side this may be hot stamped if molding is not possible)

3)Manufacturer Name

4)Manufacturing location (e.g. “Made in the U.S.A.”)

5)Recycle Symbol & % of Regrind (plastic only)

6)Production date

  1. Tray design shall include an identification colored stripe, when required,for alternation orientation purposes or different part holding capabilities.
  2. Color designation shall be determined by ChryslerPlant Engineering and may be production department dependent.

1.9 DESIGN

  1. Chrysler container types include, but are not limited to, injection molded plastic containers, thermoformed trays, wire baskets, large plastic/steel tubs, totes and steel racks with plastic inserts. The use of corrugated board, paper, wood, or other fibrous material is not permitted; PVC or oil-impregnated paper is an exception as a rust inhibitor.
  2. Design criteria specified by Product Engineering and the Powertrain facility must be incorporated into the container design.
  3. Container design shall prevent part to part contact. Distance between parts shall be no less than 0.25” and must incorporate appropriate features, such as handles, and clearances, as when being used in combination with mechanical devices such as spears, lift assists or grippers.
  4. Special attention shall be given to protect all critical part surfaces, (e.g., machined surface, bore, etc.) as called out on the part print.
  5. Container design and material typemust prevent debris contamination caused by shaving or deterioration of material.
  6. Container design shall optimize the part density; target container density is 2 hours of product rate.
  7. Container must be capable of withstanding both manual load/unload and robotic load/unload when directed by Chrysler Engineering.
  8. The container, trays and/or pallet shall partially nest to allow stacking. The transference of weight through the part when stacking is not permitted unless written approval is obtained by Chrysler’s Plant and Product Engineering prior to the design submittal. The nested loadmustbe able to withstand the dynamics of transportation and handling.
  9. Common components (e.g. manufacturer, sizes) should be selected, where deemed fit, to reduce the number and variety of spare parts.
  10. Castings or large insensitive components shall be bulk contained in larger tubs, wire baskets or racks, with or without corrugated plastic liners.
  11. Small components such as bolts, pins or springs shall be contained in standard Chrysler totes, utilizing plastic bags where required for cleanliness.
  12. The design for all unit loads or containers requiring pallets shall fit one of the Chrysler standard pallet footprints, 48”x 45” or 30” x 32”. Other container sizes are acceptable only with Chrysler Plant Engineering approval and may be dependent on space availability within the specific workstation.
  13. Container must be capableof being washed; drain holes must be furnished where required.
  14. Crankshaft and Block racks shall comply to the following design criteria:

1)Racks will be of a staggered design similar to the “Industrial Container Inc.” racks with “Creative Techniques” inserts used in Mack Avenue Engine plant 2.

2)The design will allow for one side of the plastic divider to be fixed and one side to be movable. The fixed divider or the movable divider will not be able to be separated from the metal rack frame without the use of tools.

3)The design will be such that when one row of parts has been removed or added, the movable divider can be either moved to expose the next row for part unloading or make a new empty row for part loading.

4)The Crankshaft rack footprint will not exceed the dimensions specified in section 2.1.J.

5)Block racks will be designed to have a minimal footprint for the capacity required. Racks must be designed with posts and slots and the strength and stability to allow stacking of a maximum of four racks high.

1.10 ERGONOMIC STANDARDS

  1. All container designs shall comply with Section 15 of Chrysler’s Do’s and Don’ts. Refer to the following website for theErgonomic Do’s and Don’ts in their entirety.

Anything stated in this section does not relieve the supplier of their obligation to comply with the complete list of Ergonomic Do’s and Don’ts.

  1. The Chrysler Ergonomic Specialist must be entitled to review and make appropriate recommendations on the design plans at the engineering concept phase and again at the 40% process design review.
  2. Each container design shall present the component to the operator in an ergonomically correct fashion.
  3. Packaging should be designed such that the parts are easy to grasp and manipulate with one hand using no grasping tools and without the need to flip or rotate the part. Parts shall be oriented in the dunnage or racks to match fixture or point of operation loading.
  4. Trays or containers shall accommodate two hand holes or handles. Minimum hand opening size shall be 5" x 2.5" and a handle shall be 1.5".
  5. The maximum weight for manual handled containers with parts is 30 pounds.
  6. The optimum working height for part presentation is 41” with a working envelope of 36” to 48”. To meet the working height requirements the use of pallet lifts, tilt tables or other operator assists maybe required. Each workstation height and reach shall be individually reviewed.

1.11 PROTOTYPE & SAMPLE CONTAINERS

  1. After the design approval, a single part pocket sample made of wood,urethane SLA model or other material shall be developed and reviewed for approval before the injection molding or thermoformed tooling is produced.
  2. A minimum quantity of one pallet load of thermoformed trays shall be run from wood tooling to prove tray to tray integrity prior to producing the production tooling.
  3. Container prototype samples are required no later than 8 weeks after the design is approved. A preliminary prototype test and inspection will take place at the supplier’s facility prior to shipment. Final approval of the sample container will take place at the Powertrain facility.
  4. Chrysler shall supply part prints and two sample parts, upon availability, to the selected supplier.

1.12 PRODUCTION TOOLING

  1. Hard tooling design approval is obtained once the sample production run is complete. The supplier must produce one full pallet load of containers off of the production tooling and ship them to the Powertrain facility for approval evaluation. In the case where an auto load/unload is utilized, the automation supplier must approve the containers prior to shipping them to the Powertrain facility.
  2. All tooling purchased by Chrysler shall be stored at the supplier’s facility and shall notbe used for the production of parts for others. The tooling shall be released to Chrysler upon request.
  3. The hard tool for injection molding shall be cast aluminum, water-cooled with a single cavity.
  4. Trim fixtures for routing holes and finishing outer dimensions of trays shall be provided to meet container specifications with vacuum tooling.
  5. Tool identification plate shall include supplier’s name, recycle symbol, Chrysler Powertrain facility name, part name, and NPM code.

1.13 PRODUCTION BUILD

  1. The quantity of production containers/trays required, along with the ramp up timing schedule, shall be givento the supplier by Chrysler Plant Engineering. In return, the supplier shall provide the appropriate quantities and production release dates to Chrysler Plant Engineering necessary to meet the launch dates and production volume increases.
  2. All production packaging containers shall be smooth and free from surface blemishes, i.e., voids, cracks or flashing.
  3. Chrysler Plant Engineering and the automation supplier, where applicable, shall authorize container shipments to the Powertrain facility and/or the automation supplier with an “Authorization to Ship” form.

1.14 TRANSPORTATION AND DELIVERY

  1. Transportation of containers within the Powertrain facility shall bedefined by the facilities’ Material Team and documented in the programs’ Lean Manufacturing Guiding Principles. Types of material transportation include, but are not limited to, A.G.V.s, pushcarts, tugger carts and fork trucks.
  2. Design of the container size shall prevent overhang with any transportation systems.
  3. Chrysler shall determine if vibration testing of pallet loads is required.

1.15 FACTORY PAINTING

  1. Clean steel components in accordance with SSPC SP 3.
  2. Apply one prime coat of rust inhibiting primer.
  3. Apply one coat of finish paint of color selected and approved by the Plant Engineer and approved by the operating plant.
  4. Part touching surfaces or plastic trays shall not be painted.
  5. SUGGESTED SUPPLIERS
  1. Vacuum Formed Trays

1)Creative Techniques (54707)

2)Trienda (18518)

3)Peninsula Plastics (15752)

4)Concept Industries (25550)

5)TPI (Thermoformed Products Inc) (43283)

  1. Injection Molded Dunnage

1)Creative Techniques (54707)

2)Molded Material (48804)

3)Sur-Form (48631)

  1. Steel Containers

1)AWP (86442)

2)DQSI (15138)

3)Tru-form (92021)

  1. Racks

1)Kokomo Metal Fab (55580)

2)Industrial Container (57736)

3)Tru-form (92021)

4)Salco (84365)

  1. Corrugated Dunnage

1)Creative Foam (27698D)

END OF SECTION 15990

DUNNAGE AND CONTAINERIZATIONSECTION 15990

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