toyota motor engineering

TOYOTA MOTOR ENGINEERING & MANUFACTURING NORTH AMERICA, INC.

S L I M Supplier Logistics Instruction Manual

Chapter 3 – North American Packaging

**IMPORTANT DOCUMENT CONTROL INFORMATION**

The information contained in this communication is confidential and proprietary. It is the property of Toyota Motor Engineering & Manufacturing North America, Inc.

Any printed copy of this document is considered an uncontrolled version and may not be current. The electronic version located at

ToyotaSupplier.com is the controlled and current version.

Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3

October, 2015 Manufacturing North America Page 1 of 126

Table of Contents

0. PACKAGING OVERVIEW ........................................................................................................................ 4

A. Introduction.............................................................................................................................................. 4

B. Packaging Definitions .............................................................................................................................. 4

C. Toyota Packaging Policy –North America (Reference SLIM chapter 7.7 for Export) ............................ 5

D. VPACS Introduction................................................................................................................................. 5

E. High Level Packaging Development Schedule with Milestones .............................................................. 5

F. Packaging Development – Roles & Responsibilities <N-18 to N+2> .................................................... 7

G. Packaging Operations – Roles & Responsibilities < SOP to Build Out>: ............................................. 9

H. North American Standards .................................................................................................................... 12

1. Packaging Specification Standardization for all NAMC’s ................................................................. 12 2. Container Identification ..................................................................................................................... 13

3. Returnable Packaging Use ................................................................................................................. 13 4. Handheld Returnable Tote Standards ................................................................................................ 14

5. Pallets and Top Caps .......................................................................................................................... 18 6. Plastic Bulk Knockdown (KD) Containers ......................................................................................... 18

7. Steel rack standards............................................................................................................................ 21 8. Stackable Trays................................................................................................................................... 28

9. Container Code Naming Logic ........................................................................................................... 29 10. Expendable packaging requirements .................................................................................................. 31 11. Safety and Ergonomic Standards ....................................................................................................... 35

12. Testing Standards ............................................................................................................................... 37 13. Hazmat Compliance ........................................................................................................................... 40

14. Returnable Packaging Transportation Process ................................................................................. 40

I. Packaging Purchase Process ................................................................................................................. 41

J. Returnable Packaging Ownership ......................................................................................................... 50

K. Packaging Quantity Allocation Visualization ........................................................................................ 51

L. Shortage Investigation & Reimbursement ............................................................................................. 52

M. Supplier Issue Resolution Process ......................................................................................................... 54

1. VPACS OVERIVEW................................................................................................................................. 56

A. VPACS Registration ............................................................................................................................... 56

B. VPACS - Adjust User Settings ................................................................................................................ 56

C. VPACS Tracking Screen Details ............................................................................................................ 57



2. PACKAGING DEVELOPMENT ............................................................................................................. 58

A. High Level Schedule with Milestones .................................................................................................... 58

B. Project Kick Off ..................................................................................................................................... 58

C. Pre Packaging Proposal Form Completion and Approval.................................................................... 59

D. Trial Authorization and Ship ................................................................................................................. 63

E. Trial Review and Approval .................................................................................................................... 69

F. Final Packaging Proposal Form (PPF) Completion............................................................................. 69

G. Final Packaging Authorization .............................................................................................................. 71

H. Packaging Readiness ............................................................................................................................. 74

I. First Piece Verification .......................................................................................................................... 75

J. Expendable (Back Up) Packaging Development ................................................................................... 76

3. PACKAGING OPERATIONS .................................................................................................................. 77

A. VPACS Part and Packaging Data Integrity........................................................................................... 77

B. Packaging Shortage & Reimbursement: EXCEPT TMMC: .................................................................. 77

C. Packaging Shortage & Reimbursement: TMMC ................................................................................... 80

D. Returnable Packaging Quantity Replenishment .................................................................................... 81

E. Container Re-label / Re-stencil Requirement ........................................................................................ 83

F. Preventative Maintenance, Cleaning & Repair ..................................................................................... 85

G. Post SOP Returnable Packaging Change Request ................................................................................ 90

H. Delivery Problem Report (DPR) ............................................................................................................ 92

I. Irreparably Damaged Packaging Notification Process (TMMC ONLY) .............................................. 95

J. Damaged Skid and Lid Process (TMMC ONLY) ................................................................................... 96

K. Packaging Disposition ........................................................................................................................... 97

4. GENERAL INFORMATION ................................................................................................................... 99

A. Toyota Party Contacts ........................................................................................................................... 99

B. Supplier / Fabricator Contact Information............................................................................................ 99

C. Document Reference .............................................................................................................................. 99

D. Process Reference .................................................................................................................................. 99



5. APPENDIX A .......................................................................................................................................... 100

A. Steel Rack Material Specifications; Sec. 3.0.H.7.d.............................................................................. 100

B. Steel Rack Drawings; Sec. 3.0.H.7.f .................................................................................................... 103

C. Steel Rack Quality Check Sheet; Sec. 3.0.H.7.g .................................................................................. 106

D. Quantity Allocation Visualization; Sec. 3.0.K ..................................................................................... 107

E. Trial Shipment Sheet (example); Sec. 3.2.D.8.a .................................................................................. 108

F. Packaging Shortage & Reimbursement; Sec. 3.3.B ............................................................................. 109

G. TMMC Packaging Shortage Process Flow; Sec. 3.3.C.2 .................................................................... 111

H. TMMC Expendable Packaging Tracking Sheet; Sec. 3.3.C.3 ............................................................. 112

I. Daily Rack Inspection Check Sheet; Sec. 3.3.F.2.b ............................................................................. 113

J. Bi-Annual Rack Certification Check Sheet; Sec. 3.3.F.2.c .................................................................. 114

K. Damage Repair Tag; Sec. 3.3.F.4........................................................................................................ 116

L. Packaging Change Request Form; Sec. 3.3.G ..................................................................................... 117

M. Delivery Problem Report (DPR); Sec. 3.3.H ....................................................................................... 118

N. Packaging Disposition; Sec. 3.3.k ....................................................................................................... 119

O. TMMC Challenger ASN: Sec. 3.3.H ................................................................................................... 122

P. TMMC Challenger Bill of Lading: Sec. 3.3.H .................................................................................... 123

Q. High Level Schedule with Milestones: Sec. 3.0.E ............................................................................... 125



0. PACKAGING OVERVIEW

A. Introduction

1. Background: a) Toyota Party requires that all parts shipments to its NAMC’s be made using returnable

containers. Certain situations may allow the use of expendable packaging, but it must always be approved by

the NAMC Packaging Specialist.

b) The preferred returnable packaging includes, but is not limited to: Steel racks and bins.

Plastic totes, pallets, top caps and bulk containers.

c) Also, when applicable, returnable dunnage is used to secure and protect the parts within the returnable container. Dunnage must not be permanently fixed to the returnable container.

d) Verification, timely notification and dedicated action plans are the joint responsibility of the

NAMC, Supplier and Fabricator. This will guarantee the necessary returnable packaging quantities and workability to meet daily operational requirements for safe parts delivery to the NAMC.

2. Purpose: The purpose of this section of SLIM is to provide the supplier and Fabricator with guidelines and requirements needed for a successful returnable packaging program. It will address both common and unique processes between all NAMC’s.

3. Intent: a) Provide the Roles and Responsibilities guideline for Packaging Development (N-18 to N+2)

and Packaging Operations (SOP to build out) between the Toyota Party, Supplier and Fabricator.

b) Provide Toyota standard packaging specifications, VPACS instruction & overview, packaging

development processes and daily operations procedures.

c) Objectives:

Right packaging

Right amount

Right time

B. Packaging Definitions

a) For packaging definitions refer to Chapter 1.3



• One Voice to Supplier and Fabricator

• Visualize total Pkg network

• Authorizations and PPF same system

• Visibility to both Supplier and Fabricator

Fabricator Supplier

TABC

TMMBC

TMMC TMMITMMK

TEMA

TMMAL TMMMS

TMMTX

TMMWV

V-PACS

C. Toyota Packaging Policy –North America (Reference SLIM chapter 7.7 for Export)

1. Toyota Party’s policy regarding returnable packaging for Suppliers is outlined in Section 2.4(d) of the Terms.

2. Toyota Party’s policy regarding returnable packaging for Fabricators is outlined in TEMA Indirect Supplier Terms and Conditions located in the Supplier Guide on ToyotaSupplier.com.

D. VPACS Introduction

1. VPACS is an interactive ToyotaSupplier.com packaging database that is used to design, trial, authorize, and manage pre and post production packaging activities between the Toyota Party, Supplier and Fabricator.

2. Supplier and Fabricator must ensure at least one team member has capability to manage and maintain the VPACS database with accurate information.

3. The benefit is to improve overall packaging development and operational processes: a) Improve design efficiency and standardization b) Standardize processes c) Increase communication d) Visualize project milestones e) Allow “One Voice” to Suppliers and Fabricators

4. VPACS data is utilized by multiple groups, therefore it must be accurate. Groups include:

a) Toyota Party

Production Control

Logistics Control

Purchasing

Parts Ordering

Logistics Route Planning b) Supplier c) Fabricator

5. Supplier is responsible to confirm the below information is correct in VPACS during packaging

development and also throughout the model life: a) Weight: Part and single container; Must be entered in kilograms (kg). b) Dimensions: Part and single container; Must be entered in millimeters (mm). c) Quantity Parts per Container (QPC): Single container and full pallet. d) Pictures: Correct picture of part, dunnage and container. e) Contact: Supplier contact information must be kept current.

E. High Level Packaging Development Schedule with Milestones



1. Below is a generic timeline for new model development. It may vary slightly for each project. Your NAMC Packaging Specialist will provide exact dates at project start.

2. Key milestone dates for each model can be found in VPACS.

Please refer to the North American Packaging Development High Level Schedule in the Appendix section of this manual.

North American Packaging Development High Level ScheduleN-36 N-35 N-34 N-33 N-32 N-31 N-30 N-29 N-28 N-27 N-26 N-25 N-24 N-23 N-22 N-21 N-20 N-19 N-18 N-17 N-16 N-15 N-14 N-13 N-12 N-11 N-10 N-9 N-8 N-7 N-6 N-5 N-4 N-3 N-2 N-1 SOP N+1 N+2 N+3

PROJECT

VEHICLE

MILESTONES

Reference

N-6 Begin 5 days after receiving Auth; Refer to Sec. 3.0.I for Purchasing process.

SUPPLIER

N-10

NAMC

NAMC

Final PPF approval process

NAMC

SUPPLIER Supplier ship to NAMC

NAMC Receive, review & approve/reject If reject; Supplier / Fabricator create changes & repeat V-PACS steps 5-7

N-13 N-10 Step 6

N-13 N-6 Step 7

Supplier submit Final-PPF in V-PACS

NAMC review / approve

Supplier / Fab begin procurement

Packaging authorization

Packaging readiness

NAMC

NAMC

Actual readiness

Forecast readiness

Previous model Pkg disposition

1st piece ship verification

Budget tracking

Step 3 Supplier submit standard & cost efficient design if no BM design provided.

NAMC N-16 N-10 Step 4 NAMC may approve, reject and/or request changes to proposal.

CommentsV-PACS Step

N-18

N-16 N-13

NAMC Upload new part list into V-PACS

NAMC Send Pre-PPF to Supplier

N-17 N-15

N-16 N-10

N-18 N-18

N-18 N-18

N-16 N-10

N-13 N-6

N-10 N-6

N-10 N-6

N-10 N-8

N-10 N-6

N-10 N-3

N-6 N+3

N-10 N-3

N-10 N-6

N-3 N+2

N-15 N+3

AC confirmation

Pre-PPF approval process

Prototype authorization

Trial approval process

Supplier submit Pre-PPF in V-PACS


Milestone Name

Advanced planning digital assembly activity

New model budget creation

Advanced Concept (AC) development

Responsibility

TEMA / NAMC

NAMC

TEMA / NAMC

SUPPLIER

TEMA / NAMC

SUPPLIER

NAMC

SUPPLIER

SUPPLIER

SUPPLIER

NAMC

NAMC

FinishStart

N-36 N-18

N-32 N-16

N-27

SUPPLIER

Develop & gain consensus on Benchmark (BM) design for high cost parts.

Supplier confirm if AC BM design is ok.

Step 1 Will upload as soon as available; often delayed

Step 2 Will send BM proposal if developed in AC development

Step 5 Supplier / Fabricator create prototype, test and review at Supplier facility.

Step 10

Step 8 Supplier to confirm ALL data in PPF is correct.

Step 9 NAMC may reject and/or request changes to proposal.

NAMC / TEMA will provide disposition on obsolete pkg; Refer to Sec. 3.3.J.

Step 12 Enter ACTUAL date packaging is received at Supplier facility.

Step 11 Enter FORECAST readiness date based on fabricator schedule.

NAMC confirm packaging specs at first shipment receipt

Previous Model Packaging Disposition

VSP AS K4 SE Genzu CF 1W

1A

2W

2A SOP

Advanced Planning (AP) Digital Assembly Activity

Advanced Concept (AC) Development AC

Confirmation

Pre PPF Approval

New Model Budget Creation / Pkg Qty Calculation

Proto Authorization

Trial Approval Process

Final PPF Approval

Pkg Authorization

Budget Tracking

Packaging Readiness

1st Pc Ship Verification

QCS /

LO Part List release & upload /

Send Pre PPF to Supplier

D

E

A

B

C F

G

H

I

J

K

L

M

O

N

D

E

A

B

C

F

G

H

I

J

K

L

M

O

N



F. Packaging Development – Roles & Responsibilities <N-18 to N+2>

Lead Support

1 TEMA Pkg NAMC PkgToyota Party will provide returnable packaging standard specifications and

recommended packaging style to the Supplier.3.0.H

2

TMMC

Container

Sourcing

TMMC PUR TMMC PkgTMMC PUR will provide the Supplier with a pre-approved Fabricator for all

parts. 3.0.I.2

a - Steel: ALL containers TEMA PURNAMC and

TEMA Pkg

- For prototype and concept development, TEMA PUR will provide the

Supplier with a pre-approved Fabricator for steel containers.

- NAMC and TEMA Pkg groups will be involved in steel container Fabricator

selection.

b- Plastic: ALL returnable

with or without dunnage.Supplier

NAMC Pkg,

TEMA Pkg and

TEMA PUR

- For prototype and concept development, Supplier is responsible to obtain

support from a Fabricator for all plastic containers.

- For mass production purchasing process details, please refer to Item 8 in

this matrix or to Sec. 3.0.I.

a Standard Supplier NAMC Pkg

- Supplier is responsible to provide returnable packaging that meets Toyota

Party standards and design style specifications.

- If nonstandard returnable packaging is required, Supplier must get prior

approval from the NAMC.

3.0.H

b Detail Design Supplier NAMC Pkg

- Supplier is responsible for design.

- Supplier is responsible to identify any environmental factors,

internal/external handling methods or manufacturing processes that could

impact integrity of returnable packaging function.

(Ex: temperature, water, rust, contaminants, transit mode, lead-time, etc)

3.2.C.2

c Quality Ownership Supplier NAMC Pkg

Supplier is responsible to provide RETURNABLE PACKAGING THAT

ENSURES PART QUALITY from Supplier production process, through

Toyota Logistics network and finally to NAMC part unload.

3.2.C.3

d Testing Supplier NAMC Pkg

- Testing may be required to ensure part and returnable packaging quality

throughout the supply chain network.

- Supplier is responsible to have parts dedicated for prototype fabrication,

testing and trials.

- Part availability for specific packaging development activity is required.

- Planning for part availability should be included in the vehicle development

schedule.

- Toyota Party will not reimburse for parts.

3.0.H.12

e Safety Supplier NAMC PkgSupplier is responsible to provide returnable packaging that ensures team

member safety throughout entire supply chain network.3.0.H.11

f Expendable Packaging Supplier NAMC Pkg

- Supplier is responsible to design expendable packaging (back-up) in case

of returnable packaging shortage.

- Design must have same dimensions and QPC as returnable container and

must meet all standards, quality and safety requirements.

- Design must be tested, finalized, approved & available by QCS.

- Supplier must have min. of 2 days expendable packaging available by

QCS.

- For steel containers, contact NAMC Packaging Specialist for direction.

3.2.J

g Approval NAMC Pkg

Toyota Party approval is based on the assumption that the Supplier ensures:

- Returnable & expendable packaging is within standard specifications.

- Returnable & expendable packaging has been tested in accordance to

ASTM standards and meets quality & safety requirements.

- Returnable & expendable packaging can withstand all unique environmental

factors that have been identified.

- V-PACS data is accurate.

3.2.E

h Rack / Dunnage Drawing Fabricator Supplier

Fabricator is responsible to:

- Create drawing of the approved returnable packaging design.

- Use the standard drawing template provided by TEMA.

- Submit all drawings to TEMA and associated NAMC when design is

finalized.

- Drawing format required: .IGS or .STP and .PDF.

- Method to send .IGS or .STP: via CD or BBS mailbox.

- Method to send .PDF: via email.

3.0.H.7.f

3.0.I.1

SLIM

SectionItem Key Elements

4

ALL Containers

Responsibility

NAMC's

Returnable

Packaging

Sourcing (Except TMMC)

Container Standard Specifications

3

Packaging

Design

Tier I responsible to design returnable packaging that ensures part quality throughout entire netw ork.

Supplier Production

Process

Toyota Logistics

Network

NAMC

Conveyance Part Removal



Lead Support

5 Supplier NAMC Pkg

Throughout packaging development AND model life, Supplier is responsible

to confirm the below info is correct in V-PACS:

1. Weight: Part, single empty container; Must be entered in Kg.

2. Dimensions: Part, single container, full pallet Must be entered in mm.

3. Quantity Parts per Container (QPC): Single container and full pallet.

4. Pictures: Correct picture of part, dunnage & returnable container.

5.Contact: Supplier contact information must be kept current.

3.0.D

&

3.2.C.4

6

All NAMC Pkg

Groups:

Authorize

TEMA Pkg:

Standardize

Method

Toyota Party will calculate the total quantity of returnable packaging required

to fill the Toyota supply chain network.

3.0.K

7

TMMC

Returnable

Packaging

Procurement

TMMC PUR TMMC Pkg

Approved returnable packaging will be purchased by TMMC PUR using pre-

approved Fabricators.

3.0.I.2

a

- Steel: ALL containers.

- Plastic: ALL standard

containers with NO

dunnage.

TEMA PURNAMC and

TEMA Pkg

Approved returnable packaging will be purchased directly by TEMA PUR

using approved Fabricators.

Returnable packaging types purchased directly by TEMA PUR include:

* Steel containers

* Standard plastic containers with NO DUNNAGE.

b

- Plastic: ALL standard

containers WITH

dunnage &

ALL non standard

containers with or

without dunnage.

Supplier

NAMC Pkg,

TEMA Pkg and

TEMA PUR

Approved returnable packaging are purchased by Supplier, and reimbursed

by TEMA PUR through WARP.

Returnable packaging types purchased directly by Supplier::

* Standard plastic returnable packaging WITH DUNNAGE.

* Nonstandard plastic returnable packaging (with or without dunnage).

a TMMC TMMC TMMC will retain ownership of returnable packaging.

bNAMC's

(Except TMMC)

Supplier:

Owner of

returnable

packaging.

NAMC Pkg:

Exclusive right

to reallocate

returnable

packaging at

any time for any

project.

- Please refer to Section 2.4(d) of the Terms.

- Supplier must have Toyota Party written agreement to utilize

returnable packaging outside of the program that it was

allocated.

3.0.J

3.0.I.1

SLIM

Section

Returnable

Packaging

Ownership

NAMC

Returnable

Packaging

Procurement (Except TMMC)

Key Elements

9

8

V-PACS Part and Packaging Data Integrity

Returnable Packaging Quantity Allocation

Visualization

ALL packaging.

Responsibility

Item

Supplier Inventory(Dependent on P/U

Frequency)

Transit Time(inc. Yard, Cross Dock &

Separation Center)

NAMC Inventory (Dependent on

Delivery Frequency)

NAMC Pkg / TEMA PUR sends

authorization to Supplier

Supplier procures

returnable packaging

Supplier receives returnable

packaging & confirms quality

TEMA PUR issues PO to Supplier for

reimbursement

TEMA PUR issues PO to Fabricator

Fabricator produces returnable packaging

TMMC issues PO to Fabricator

Supplier receives returnable packaging & confirms quality

Supplier receives returnable packaging & confirms quality

Fabricator produces returnable packaging



G. Packaging Operations – Roles & Responsibilities <SOP to Build Out>:



Verification /

Notification Payment

aSupplier

Initiated

Ship Point

Location Change

<FOB>

Supplier Supplier SSCR

Supplier Responsibility:

Procure, receive and insert returnable

packaging into system by SOP of new ship

location.

Vehicle or Part

Volume Increase

NAMC Pkg

(from TEMA

PP)

NAMC Pkg 13 Week Forecast

ECI

NAMC Pkg

(from TEMA

PPM)

NAMC Pkg SMS BR

Logistics Route

Design Change

NAMC Pkg

(from TEMA

Log)

NAMC Pkg

- SCNC Packet (Supply Chain

Network Communication):

Region Changes

- Period Change Over Packet:

Volume File

Ship Point

Location Change

<FOB>

NAMC Pkg

(from TEMA

Log)

NAMC Pkg

SCNC Packet (Supply Chain


SSCR (Supplier Shipping

Change Request) File

cNAMC Pkg /

Supplier

NAMC Pkg /

Supplier

Data collected from:

- Supplier tracking form

- Supplier shortage

investigation

- Toyota Party shortage

investigation

- NAMC & Supplier shortage investigation activity

must be completed to confirm shortage is due to

Operational Loss/Attrition. (Please refer to Item 5 if

shortage is not due to operational loss/ attrition).

- If Toyota purchases additional returnable

packaging for Toyota logistics network due to

attrition, these are not to be utilized for non Toyota

logistics network purposes.

aSupplier

Initiated

Ship Point

Location ChangeSupplier Supplier Supplier


Procure, receive and apply new labels /

stencils to all returnable packaging in the

system by SOP of new ship location.

Logistics Route

Design Change

NAMC Pkg

(from TEMA

Log)

NAMC Pkg

- SCNC packet (Supply Chain


Region Changes

- Period change over packet:

Volume File

Ship Point

Location Change

NAMC Pkg

(from TEMA

Log)

NAMC Pkg

SCNC Packet (Supply Chain


SSCR (Supplier Shipping

Change Request) File

aNAMC Pkg /

SupplierSupplier

- Supplier to manage

activity and cover costs

associated.

- Supplier / NAMC user

group notification

- Supplier responsible to ensure returnable

packaging is clean, safe and in good working order

prior to pick up from their facility.

- Returnable packaging is designed for internal use

only; Supplier assumes cost for repair, replacement

or cleaning if returnable packaging is kept outside.

- Cost associated with cleaning and preventative

maintenance are the responsibility of the Supplier.

- If there is a part quality issue due to lack of

maintenance, Supplier is responsible for scrap,

rework or repack costs.

- Supplier can use Fabricator of choice to perform

maintenance.

bNAMC Pkg /

Supplier

NAMC Pkg /

Supplier

- Supplier to manage

activity.

- Toyota Party to review

claim & reimburse

costs based on point of

cause.

- Supplier / NAMC user

group notification

- Both Supplier and NAMC are responsible to

identify damaged returnable packaging.

- Supplier responsible to:

*Ensure returnable packaging is damage free,

safe and in good working order prior to pick up

from their facility.

*Perform & manage repairs.

*If part quality issue due to lack of returnable

packaging repair, Supplier is responsible for

scrap, rework or repack costs.

- NAMC responsible to:

*Investigate repair reimbursement request and

determine point of cause.

*NAMC cause of damage = NAMC provide

reimbursement to Supplier.

*Supplier cause of damage = NAMC does not

provide reimbursement to Supplier. (Through the

“Issue Resolution” process, the Supplier can

escalate by providing additional explanation.)

SLIM

Section

Returnable

Packaging

Preventative

Maintenance,

Cleaning &

Repair

Returnable Packaging

Preventative Maintenance and

Cleaning

Returnable Packaging Repair

Information Source Key Elements

3.3.D

3.3.E

3.3.F

Toyota

Party

Initiated

Operational Loss / Attrition

3

Responsibility

Item

2

Returnable

Packaging

Re-label /

Re-stencil

Requirement

Quantity

Replenishment1

b

b

Toyota

Party

Initiated

Toyota Party Responsibility:

Purchase returnable packaging direct

from Fabricator or authorize Supplier to

purchase returnable packaging on their

own.

Refer to Section 3.0.I.1 for guidelines.


Procure (if not purchased direct from Toyota

Party ) , receive & insert returnable

packaging into system at time of change

implementation.

Toyota Party Responsibility:

Authorize labels.


Procure, receive and apply new labels /

stencils to all returnable packaging in the

system by SOP of new ship location.



Verification /

Notification Payment

a Supplier NAMC PkgV-PACS post SOP design

change request

- Supplier to provide cost, quality &/or safety benefit

analysis using the "Packaging Change Request

Form".

- Toyota Party will approve or reject returnable

packaging specification changes via V-PACS after

evaluation.

- Toyota Party to provide detail if rejecting design

request; Further negotiation between Toyota Party

& Supplier to reach consensus.

bNAMC Pkg /

SupplierNAMC Pkg

- Toyota Party notification /

request to Supplier

- Supplier: V-PACS post SOP

design change request

- Toyota Party to provide safety, cost quality &/or

productivity benefit analysis.

- Supplier to submit Post SOP design change

request in V-PACS as "approval" of design change.

- Supplier to provide detail if rejecting design

request; Further negotiation between Toyota Party

& Supplier to reach consensus.

cNAMC Pkg /

Supplier

NAMC Pkg /

SupplierDPR

- Ergo Issue @ Supplier = Supplier Responsibility

- Ergo Issue @ NAMC = NAMC Responsibility

dNAMC Pkg /

SupplierSupplier DPR

- Supplier is responsible to design and maintain

returnable packaging that ensures quality

throughout entire process. (Reference Sec. 3.0.F

"Packaging Development Roles & Responsibilities",

4.c).

- Supplier is responsible for any part defects

caused by the returnable or expendable packaging.

- All sort and scrap costs associated with

packaging caused defects are the sole

responsibility of the Supplier.

a Supplier SupplierSupplier returnable packaging

shortage investigation

Supplier is responsible for the cost of expendable

packaging, expedites & any other expenses caused

by returnable packaging shortage, if returnable

packaging intended for transportation loop between

NAMC and Supplier is utilized for:

- Tier II

- Off site warehouse

- Work in process (WIP)

- Other NAMC's or OEM's

- Internal bank build or quality issue

b NAMC Pkg NAMC PkgToyota Party shortage

investigation

Toyota Party is responsible for the cost of

expendable packaging, expedites & any other

expenses caused by a returnable packaging

shortage if:

- Quantity allocated is not sufficient for transit lead

time changes

- Inventory in overflow, OS&D or QC/RI

- Build up of returnable packaging at NAMC, yard or

Cross Dock

6 Supplier NAMC PkgSupplier verification /

notification

Throughout packaging development AND model life,

Supplier is responsible to confirm the below info is

correct in V-PACS:

1. Weight: Part, single empty container; Must be

entered in Kg.

2. Dimensions: Part, single container, full pallet

Must be entered in mm.

3. Quantity Parts per Container (QPC): Single

container and full pallet.

4. Pictures: Correct picture of part, dunnage &

returnable container.

5.Contact: Supplier contact information must be

kept current.

3.3.A

a Supplier NAMC PkgNAMC instruction to Supplier.

*Must be in writing.Supplier to use for current / new model.

b NAMC Pkg SupplierNAMC instruction to Supplier.

*Must be in writing.

Returnable packaging is modified to support new

part or part design change.

c TEMA Pkg SupplierTEMA & NAMC instruction to

Supplier.

*Must be in writing.

- TEMA to solicit other NAMC's to find other uses.

- TEMA to instruct Supplier to:

*Send to Toyota Party Warehouse OR

*Recycle with Pre-Approved Toyota Party recycle

company. (Company contact information will be

provided).

3.3.G

3.3.k

3.3.B

&

3.3.C

Returnable

Packaging

Specification /

Design Change

SLIM

SectionItem

Responsibility

Information Source Key Elements

Quality Issue

4

Supplier Initiated Kaizen

Safety Issue

Toyota Party Initiated Kaizen

7

Returnable

Packaging

Shortage /

Expendable

Container Usage

Supplier Responsible

Toyota Party Responsible

No future need

Retrofit

V-PACS Part and Packaging Data Integrity

Carryover

5

Returnable

Packaging

Disposition:

Production

Build out



Inside Trailer

Waste Space

:Nonstandard

:Standard

H. North American Standards

1. Packaging Specification Standardization for all NAMC’s

a) Standard: Standard packaging specifications are necessary to ensure:

o Safety o Quality o Productivity o Cost

b) Nonstandard: NAMC Packaging Specialist will not approve nonstandard packaging unless there is no other option. Nonstandard packaging negatively impacts safety, quality, productivity and cost.

Examples: o Safety: Nonstandard packaging creates unstable stacking conditions.

o Quality: Part damage during transportation due to poor stacking conditions.

o Productivity: Nonstandard packaging causes wasted space in trailers.

Individual containers may appear to be more efficient, but the actual condition is an inefficient shipping condition when evaluating impact to overall network.

Cost: Future model reuse and flexibility between models is unlikely with nonstandard packaging. Nonstandard packaging is often part specific and therefore cannot be utilized for any

other current or future commodities.

Steel

rack

Totes: Racks:

:Nonstandard

:Standard

:Nonstandard

:Standard



2. Container Identification

a) Standard Correct identification is the only return instruction for the NAMC’s and Logistics Providers.

Without the correct identification, Toyota Party CAN NOT GUARANTEE the return of returnable packaging.

Upon receipt of labels, confirm label data is correct.

b) Nonstandard Toyota Party CAN NOT GUARANTEE the return of returnable packaging that has no

labels, labels with incorrect data or labels not properly applied. Example of labels incorrectly applied:

o New label was placed on top of original label. This is NOT acceptable. The new label is likely to fall off, as seen in below photo. It is unclear which label is correct.

3. Returnable Packaging Use

a) Returnable packaging purchased by Toyota Party is for use ONLY within the Toyota network. b) DO NOT USE TOYOTA RETURNABLE PACKAGING, including PALLETS/LIDS FOR:

Other OEM’s, Tier II shipments, warehouses, direct supply or any destination outside of the Toyota Party network; or

Internal requirements above the quantity allocated by Toyota Party: Example: Work In Progress (WIP), service parts, build ahead, quality quarantine, etc.

c) If additional returnable packaging and labels are required, the Supplier must purchase the additional amount.

d) Refer to “Quantity Calculation Visualization” Section 3.0.K.1

e) If totes or pallets with the “PROPERTY OF NUMMI” hot stamp have been allocated to you,

please treat the same as a “TOYOTA SHIPMENT” pallet. There is no need to cover the NUMMI hot stamp.



Manufacturer Color Color Number

Orbis Gunmetal Grey 82-145-1

Schaefer Charcoal Grey 7AC722288MBUV

4. Handheld Returnable Tote Standards

a) General Information

Orbis and Schaefer are Toyota Party approved Fabricators.

Max weight per tote including dunnage & parts: 15kg.

2 Kanban holders required per tote: o Standard location: Holders on adjacent sides; exception if design restriction. o The Kanban holder must be attached to the unload side of the tote for line side

verification of the part. o Corrugated plastic totes: Kanban must be recessed and securely attached.

Standard tote color is grey.

Tote stacking within each individual Supplier is required. Avoid selecting a mixture of totes that when combined don’t create a proper (square, level and stable) pallet configuration.

Maximum tote stacking height with pallet and top cap: 50”. b) Dunnage Requirements

Dunnage may be required to separate and/or protect parts during shipment.

Dunnage MUST NOT be permanently attached to the tote with rivets, glue, etc. (Permanent attachment will prevent flexibility for future reuse).

If dunnage is used, temporary attachment method is required; Velcro is recommended. o Loose dunnage (corrugated pad, plastic bag, etc.) is NOT permitted.



Dimensions and Codes

Standard straight wall totes:

Standard folding totes:

Nonstandard totes: o DO NOT USE a nonstandard tote without approval from NAMC. o Includes:

Any size not listed in the standard tote sections. Corrugated plastic totes.

o 32” & 36” totes have been discontinued. DO NOT USE. o Nonstandard tote dimensions must be chosen to allow for proper pallet configuration on

a standard 48”x45” pallet. Example: 24”x24” totes do not allow building a stable, stackable pallet for shipping.

o Height dimension must be equal to or a multiple of one of the standard tote heights to allow for level pallet configurations when mixed with standard totes.

STANDARD

Pkg Code

Unique

Character

Length

(mm)

Width

(mm)

Height

(mm)

Orbis (ORB)

Part Number

Schaefer (SSI)

Part Number

Kanban

Location

ST121504-F F: Flat bottom 305 381 102 MSO1215-4M NF121504XS Opposite

ST121507-F F: Flat bottom 305 381 191 NSO1215-7M NF121507AS Adjacent

ST241504 610 381 102 MSO02415-4R NF241504XP Opposite


ST241507 610 381 191 NSO2415-7R NF241507AP Adjacent


ST241511 610 381 280 NSO2415-11R NF241511AP Adjacent

ST241514 610 381 368 SO2415-14R NF241514AP Adjacent


ST242207 610 572 191 NSO2422-7R AF242207AC Adjacent

ST242211-F F: Flat bottom 610 572 280 NSO2422-11M AF242211XS Adjacent

ST242211 610 572 280 NSO2422-11R AF242211XC Adjacent

ST242214-F F: Flat bottom 610 572 368 NSO2422-14M AF242214XS Adjacent

ST242214 610 572 368 NSO2422-14R AF242214XC Adjacent

ST481507 1219 381 191 SO4815-7R AF481507AP Adjacent

ST481507-H H: Hand holes 1219 381 191 n/a AF481507HP Adjacent

ST481511 1219 381 280 SO4815-11R AF481511AP Adjacent

ST481511-H H: Hand holes 1219 381 280 n/a AF481511HP Adjacent

STANDARD

Pkg Code

Unique

Character

Length

(mm)

Width

(mm)

Height

(mm)

Orbis (ORB)

Part Number

Schaefer (SSI)

Part Number

Kanban

Location

SF121507 n/a 305 381 191 n/a CF121507AS Adjacent

SF241507 n/a 610 381 191 n/a CF241507AP Adjacent



SF242207 n/a 610 572 191 n/a CF242207FP Adjacent





Straight Wall Tote Folding Tote Incorrect Size & Color Corrugated Plastic Tote

Standard Handheld Container (tote) Nonstandard Handheld Container (tote)


Standard Hand Held Container (Tote) Non-Standard Hand Held Container (Tote)

Straight Wall ToteFolding ToteIncorrect Size & ColorCorrugated Plastic Tote

Standard Hand Held Container (Tote)Non-Standard Hand Held Container (Tote)


Standard Hand Held Container (Tote) Non-Standard Hand Held Container (Tote)

Example: Standard and nonstandard totes.

c) Label specifications

Background: White

Font: Black

Quantity required per container:

If re-labeling:

o The original label must be removed.

o The container must be cleaned and dried before applying the new label.

Label Dimensions: 6.25” x 1”

Must include the following:

o NAMC Code: Refer to chart below.

o Supplier Code: 5 digit numeric code for all NAMC’s except for TMMC.

TMMC has unique codes with 4 numeric digits and one alpha digit.

o TLMS Code: 5 alpha digit Toyota North America Supplier Logistics short name; common between ALL NAMC’s including TMMC.

Upon receipt of labels, confirm label data is correct.

Supplier is responsible for additional labels unless requested by Toyota.

Tote Type Qty Labels per Tote

Tote height = 4" 2

Folding totes 2

All other sizes & types 4

4



NAMC Hot Stamp # Tote Size Font Size Font Type

Font

Color

Qty

Required

Height = 4" 36pt Arial Narrow; Regular

Height ≠ 4" 72pt Arial; Regular

2 per tote on

opposite

sides

"TOYOTA SHIPMENT"ALL White

TOYOTA SHIPMENT

1

2

TMMC [TOYOTA]

TOYOTA SHIPMENT TMMC [TOYOTA]1

2

K 12345 SUPLAC1234A SUPLA

NAMC Code

NAMC Code Font Size Font Type

TMMC C

TMMK K

TMMI I

TABC TA

TMMAL AL

TMMBC BC

TMMMS MS

SIA (TMMNK) KS

TMMTX TX

TMMWV WV

Supplier Code TLMS Code

Supplier Code TLMS Code Font Size Font Type

12345* SUPLA 56pt Arial Bold

*TMMC has unique supplier codes.

56pt

36pt

Arial Bold

1

2 3

K 12345 SUPLA

C 1234A SUPLA

1 32

6.25"

1"

Label Example: NAMC = TMMK Supplier Code = 12345 TLMS Code = SUPLA

d) Hot stamp specifications

Example: Tote label and hot stamp



5. Pallets and Top Caps

a) General Specifications:

Orbis and Schaefer are Toyota Party approved Fabricators. Standard color is black. Standard dimensions:

b) Hot Stamp Specifications:

6. Plastic Bulk Knockdown (KD) Containers

a) General specifications:

Orbis and Schaefer are Toyota Party approved Fabricators.

Standard color is black. Example: Standard bulk container; also called knockdown container.

Toyota Code Type Length (mm) Width (mm)

SP484506 Pallet 1219 1143

SL484503 Top Cap 1219 1143

NAMC Hot Stamp Hot Stamp Font Color # of Sides w/ Hot Stamp

ALL "Toyota Shipment" White 2



b) Container dimensions and codes: Standard knockdown containers:

o 45x48 should always be first choice.

o Number of doors: 25” knockdown containers: 2 doors are standard. Greater than 25”: 4 doors are standard. If a different number of doors are required, contact the NAMC Packaging

Specialist.

o Contact the NAMC Packaging Specialist for detail on which model & brand to use.

Nonstandard knockdown containers: o DO NOT USE nonstandard container without approval from NAMC. o Includes any size not listed in the standard knockdown container section. o 32” & 36” knockdown containers have been discontinued. DO NOT USE.

c) Dunnage requirements

Dunnage may be required to separate and/or protect parts during shipment.

Dunnage MUST NOT be permanently attached to the knockdown with rivets, glue, etc. (Permanent attachment will prevent flexibility for future reuse).

If attachment is necessary, a temporary attachment method is required; Velcro is recommended.

Length

(mm)

Width

(mm)

Height

(mm)

SK454825-2 1219 1143 635

SK454834-4 1219 1143 864

SK454850-4 1219 1143 1270

SK644825-2 1638 1219 635

SK644834-4 1638 1219 864

SK644850-4 1638 1219 1270

SK704825-2 1778 1219 635

SK704834-4 1778 1219 864

SK704850-4 1778 1219 1270

VPACS Code

("last #" = number

of doors)

Dimensions



d) Identification (ID) plate specifications: Background: White Font: Black

Size of ID plate is dependent on container size. o Confirm size with Fabricator.

If re-labeling: o Do not remove previous ID plate. o New ID plates must have holes to completely cover the rivets that were used to secure

the original ID plates. Specify this requirement to Fabricator when making order.

o Before applying new ID plate, previous ID plate must be cleaned and dried.

Upon receipt of ID plates, confirm data is correct.

Example: Large and small ID plates

Container

Size

ID Plate

Dimensions Font Size

Font

Color

Background

Color

Qty

Required

48x45 3.5" x 3"

64x48

70x48

4 (one each side)

WhiteBlack

Please make font as

large as will fit on

the ID Plate6" x 3"

3.5" 6"

3"

45" x 48" Bulk Container 64" x 48" Bulk Container



7. Steel rack standards

a) Length and width: 45x48 rack footprint should always be first choice.

Standard rack footprints:

Standard bin footprints:

Nonstandard footprints:

o DO NOT USE a nonstandard rack or bin without approval from the NAMC.

o Includes any size not listed above.

o 30” & 32” rack and bins have been discontinued. DO NOT USE.

o If a nonstandard rack or bin is approved, follow same naming process as above. Example: Standard and nonstandard racks and bins.

Toyota Code*

"HH" = Height Dims Description

Length

(mm)

Width

(mm)

SR4548HH 45x48 Rack 1156 1232

SR4548HH-W45 45x48 Walk in rack on 45 side 1156 1232


SR6048HH 60x48 Rack 1537 1232



SR6096HH 60x96 Rack 1537 2452

SR7548HH 75x48 Rack 1918 1232



SR7596HH 75x96 Rack 1918 2452

SR9648HH 96x48 Rack 2452 1232

SR10548HH 105x48 Rack 2680 1232

SR12048HH 120x48 Rack 3061 1232

SR15048HH 150x48 Rack 3823 1232

SR18048HH 180x48 Rack 4585 1232

* BASE/Length/Width/Height

V-PACS Code*

"HH" = Height Dims Description

Length

(mm)

Width

(mm)

SB4548HH 45x48 Bin 1156 1232

SB6048HH 60x48 Bin 1537 1232

SB7548HH 75x48 Bin 1918 1232

* BIN/Length/Width/Height



Rack Bin Rack Bin

Standard Base and Footprint Non-Standard Base and Footprint

b) Height

Stacking height takes into consideration 1 3/4” of nesting for the stacking cap and 5/8” of nesting for the recessed bottom.

The height is measured from the base of the rack to the top of the pins.

c) Rack Color and Identification

Height

(in)

Height

(mm)

Stackable # with same

height in trailer

104" 2642 1

53" 1347 2

36" 915 3

27.5" 699 4

22.5" 566 5

19" 483 6

Item Detail

Color Gun Metal / Machine Tool / West Coast Grey

Paint Type ESD or Powder Coat (to prevent rusting)

TOYOTA, NAMC Code, Double arrow, Supplier Code, TLMS Code

Ex) TOYOTA TMMK 12345 SUPLA

ID Color Black

ID Size 1.5" (38mm) Block Capital Font

ID Location All four sides of the base

Sequential Number Two-digit year code preceding the number; ex. "10123"

Sequential # Location On 2 corner posts (inner sides if possible)

Manufacturer ID One manufacturer ID plate located on the inner side of base.

ID Information

1

2

3



d) Material specifications

Steel gauge o The standard steel size for pallet bases and posts is 2”x2”, 11 gauge. o The standard steel size for pallet skater bars is 1”x2”, 11 gauge. o Refer to the standard base drawings for details; Section 3.0.H.7.f.

Stacking caps o All racks are to have a pin and post design. This includes standard rack design and the

folding post design. o The standard stacking cap is Livonia 1738B. o The stacking caps are to be located on the top of the posts. o Stacking cap sketch: (Also in Appendix)

Kanban holders o Kanban holders must be on two adjacent sides located near a corner post. One Kanban

holder must be located near the unload side of the rack to ensure visibility for the T/M. o Please contact your NAMC Packaging Specialist to confirm specific location. o Kanban holders must be made of 11 gauge steel. o Steel Kanban holder specifications: (Also in Appendix)

ID and Sequential Number Detail:

1

0

1

2

3

1

0

1

2

3

1

1

0

1

2

3

22 If sequential number can not

be added to inner side of

corner posts due to rack

design, it is acceptable to put

on outer side of post.

TOYOTA TMMK <--> 12345 SUPLA

TOYOTA TMMK <--> 12345 SUPLA 1

SUPLA

NAMC <--> 12345

If Walk in Base:

Left Side: NAMC <--> Supplier Code

Right Side: TLMS Code

Follow standard for other 3 sides.

Manufacturer ID:

Manufacturer Name:

Country of Manufacture:

Date of Manufacture:

Rack Sequence #:

* Alumninum plate riveted to inner side of base.

TOYOTA SHIPMENT3



Front View Side View

Folding post design o In order to improve transportation efficiency, a standard folding post was developed to

utilize a better return ratio between long distant Suppliers and NAMC’s. o The NAMC will inform you if this design is required. o The design uses pin on top and recessed bottom design to allow interstackability with

standard fixed post racks. o Folding post design sketch: (Larger format in Appendix)

o Critical check points for folding post: Weld quality within specifications; weld slag can prevent movement of post. Movement of posts must be within tolerance. Post & Pin are within specification. Specifications and tolerances are defined on the drawing.



Tolerances o Final dimensions of main base and corner uprights shall be vertical in both planes within

tolerance of +/-3mm of drawing dimensions. o Diagonal dimensions across tops of posts / base shall be within +/-3mm of calculated

dimension. The measurement shall be taken from outside of each corner of post. o Other critical dimensions, such as dunnage location, MUST be specifically defined

during prototype development in each container drawing. Refer to Section 3.0.H.7.f “Drawings”.

o Supplier is responsible to define critical points and exceptions to the tolerances defined above.

e) Welding

All welding shall conform to published American National Standards Institute (ANSI) standards.

All welding joints in the base frame and between base frame and vertical columns must be fully welded.

No weld or adjacent parent metal is to be painted or galvanized until slag and excessive weld splatter have been removed from critical areas, including stacking caps, bottom corners, sharp edges, base bottom, etc.

The skater bars must be flat to ensure ability of racks to roll in conveyor.

f) Drawings Final revision drawing requirements:

o Fabricator is responsible to create final drawing of the approved design. o The standard drawing template must be used. o All drawings must be submitted to TEMA PUR/Pkg and associated NAMC Pkg when

design is finalized. o Drawing format required: .IGS or .STP and .PDF. o Method to send .IGS or .STP: via CD or BBS mailbox. o Method to send .PDF: via email.

Engineered drawings of standard footprints: o Each approved Fabricator has been provided the Professional Engineer approved

standard base and standard walk-in base drawings. Certified PE drawings may be requested for all nonstandard bases.

o Bases must be built to the specifications noted below as identified on the Professional Engineer approved drawings: Material and grade specifications Tolerance specifications Weld specifications

o It is the responsibility of the Fabricators to follow all of the above workmanship specifications. If deviations are found, the Fabricators must support the modifications process at their own cost, including on-site support, transportation of racks to their facility for repair and managing 100% quality checks before shipping back to the Supplier

o Snapshot of 45” x 48” standard base design (Larger format in Appendix)



Standard Title Block

Standard Bill of Material (BOM)

PART NUMBER SUPPLIER DATE

63102-0E100 PK USA 5/8/2009

NAMC MODEL CODE DESIGNER CHECK

TMMI 397L IDI NAME

BASE CODE DUNNAGE CODE 1 DUNNAGE CODE 2 DUNNAGE CODE 3 QPC GROSS WEIGHT

BASE0484536WI48 24 604 lbs

DIM UNITS SOFTWARE REVISION

INCH CATIA 1

DRAWING FILE NAME

MODEL_PARTNUMBER_REVISION

PROPERTY OF TOYOTA ENGINEERING & MANUFACTURING NORTH AMERICAN

VENDOR

IDI

PART DESCRIPTION

WINDSHEILD HEADER ASSY

DECIMAL TOLERANCES

UNLESS SPECIFIED

.X = 0.04

.XX = 0.06

.XXX = 0.03

.XXXX = 0.01

ANGLE TOLERANCES

UNLESS SPECIFIED

.X = 1.00

.XX = 0.50

.XXXX = 0.01

WINDSHIELD HEADER ASSY



Example: Full standard drawing (Larger format in Appendix)

g) Quality Check Sheets

In process quality checks (Fabricator lead) o Fabricator to set up quality check between each fabrication process. o This is required to ensure good quality is passed to next phase of production. o Utilize tools to support the quality confirmation process.

Example: Jigs, fixtures, check sheets, etc. o Verification that jigs/fixtures are within spec is required at each shift. o Supplier to confirm Fabricator is conducting 100% rack quality checks.

End process quality checks (Fabricator lead) o The first piece check (mass production level) is critical to confirm 100% quality. This will

ensure jigs/fixtures are to specification. o Functionality, workability, quality and specifications of each rack shall be checked to

ensure good quality and confirm tolerances are being held. o Visual check sheets must be placed on each rack after confirmation of quality has been

made. Please see example of quality check sheet below. o Supplier to confirm Fabricator is conducting 100% rack quality checks.

PART # VENDOR

1 Plastic Dunnage HDPE 12 32 10 4 Fabricated - -

2 Dunnage Bolt Stainless 4 1 - 5 Purchased xxxx-x Fastenal

IF PURCHASEDFABRICATED OR

PURCHASEDOTHER SPECQTYNAME / DISCRIPTION ITEM # HEIGHTWIDTHLENGTHMETERIALMATERIAL



Verification upon receipt (Supplier lead) o Upon rack receipt from Fabricator, Supplier is responsible to confirm rack functionality,

workability, quality and specifications of each rack to ensure quality and confirm tolerances are held. If there is an issue, the Supplier must contact the Fabricator and NAMC immediately to determine next steps.

NOTE: Supplier assumes responsibility of rack quality once they are received.

Quality check sheet example (Larger format in Appendix):

8. Stackable Trays

a. General specifications i. Vacuum formed or structural foam constructed plastic trays. ii. Trays should be designed to interlock with other trays to complete a full pallet

load. iii. Trays may either be designed to support the weight of the pallet load, or to allow

the parts packed on the trays to support the weight of the palletized load if part quality is not an issue; usually seen with forged parts such as engine blocks, crankshafts, etc.

iv. If trays are stackable and nestable, markings must be added to identify proper orientation.

Quality Check Sheet

Part Number Date

Part Description Name of Inspector

Fabricator Job Description Name of Fabricator Co.

Sequential Number

Quality Check Sheet

Product Name Date; / / OK・・・レ

LINE ASSEM 48" X 66". DWG# 070211 Name; NG・・・NG

Description 1 2 3 4 5 6 7 8 9 10

Serial Number

A 66" +0 -1/8"

B 48" +0 -1/8"

C 51-3/8 +- 1/8"

D 21-13/16" +-1/8"

E 21-1/8 +-1/8"

F 18-5/8" +-1/8"

G 33-5/16" +1/16" -0

H 15-7/8" +1/16" -0

I 37-13/16" +1/16" -0

J 25-7/8" +1/16" -0

K STENCIL BASE: (FORMAT = "NAMC Code, 12345, ABCDE")

L SER # RT FT POST LFT REAR POST

M MAKE SURE SWIVEL CASTER AND PULL ARE ON SAME END

N REMOVE SHARP EDGES AND WELD SPLATTER

O Kanban Holders (2) -adjacent sides

P

Q 0

R 0

PASS (Inspector initial)

Remark

Include all

critical rack

and dunnage

placement

dimensions.

Comments:

Description

Rack #

60.5

48.5

60.5

48.5



45x48

64x48LxW

v. Each stackable tray system must have a pallet base & top cap system, fully stackable and with 4-way fork access on pallet base.

vi. Stackable trays are part specific, and therefore are considered to be a nonstandard package type.

b. Dimensions

i. Trays are nonstandard, yet standard dimensions are required for logistics efficiency.

ii. 45 x 48 foot print should be first option. iii. Height is dependent on number of layers; max 50”.

Confirm layer quantity w/ NAMC.

c. Please refer to Section 3.2.C.6 for details on how to correctly fill out a stackable tray PPF in VPACS.

d. Label Specifications

Background: White

Font: Black

Quantity required per tray: 4

If re-labeling: o The original label must be removed. o The tray must be cleaned and dried before applying the new label.

Label dimensions: 6.25” x 1”

Must include the following: o NAMC Code o Supplier Code o TLMS Code

Refer to Sec. 3.0.H.4.d for visual example.

Upon receipt of labels, confirm label data is correct

9. Container Code Naming Logic

a) All containers will utilize a common naming process. b) Goal is to simplify and standardize data across all NAMC’s.

Examples and explanation shown below:



c) Standard container codes will be defined and established in VPACS. Please select code from existing standard code options.

Do not create a new container code.

d) If a nonstandard container is required: Contact your NAMC Packaging Specialist for approval and container code.

Container Code ExplanationExamples and explanation shown below:

19 22 27 36 53 104

45x48* O O O O O O

60x48* O O O O O O

60x96 O O O O O C

75x48* O O O O O C

75x96 O O O O O C

96x48 O O O O O C

105x48 O O O O O C

120x48 O O O O O C

150x48 O O O O O C

180x48 O O O O O C

*Walk-In base permitted.

Standard

Dimensions

H

LxW

Metal Racks

4 7 11 14

12x15 O O C C

24x15 O O O O

24x22 C O O O

48x15 C O O C

LxW

Hand-Held TotesStandard

Dimensions

H

25 34 50

45x48 O O O

64x48 O O O

70x48 O O O

H

LxW

Standard

Dimensions

Knockdown Containers

27 36

45x48 O O

60x48 O O

75x48 O O

H

LxW

Metal BinsStandard

Dimensions

1

2

43

For pallet size containers (Knockdowns, racks or bins),

use 45x48 as first option.

Standard or

Nonstandard

Container

Type L W H

Unique

Character*

Container side

w/ walk-in, door

or FW entry Container Code

S T 24 15 07 - - ST241507

S T 48 15 07 H - ST481507-H

S K 45 48 25 2D 45 SK454825-2D45

S R 45 48 53 W 48 SR454852-W48

N R 47 48 35 - - NR474835

N K 45 48 50 FWP 48 NK484550-FWP48

N V 45 48 34 044** 01** NV454834-04401

*Unique character used only if required.

**Vac Tray code will be followed by Model code & 2 digit sequential number.

1 2 3 4

Code Definition

S Standard

N Nonstandard

Code Container TypeStandard /

Nonstandard

B Metal Bin S

F Folding Tote S

K Knock Down Bulk Container S

L Top Cap (Pallet Lid) S

P Pallet S

R Metal Rack S

T Stackable Tote S

A Sequence Container N

C Corrugated Fibreboard N

D Stamping Rack (In house) N

E Dolly Exchange Rack N

I Off-fall Pallet N

N Nestable Tote N

O Other (battery trays, etc) N

S Sleeve Pack N

V Stackable Tray (Vac Form) N

X Corrugated Plastic Tote N

Code Definition

F Flat Bottom Tote

FWS Fixed wall steel

FWP Fixed wall plastic

H Hand Hole

W Walk-in Base

1D

2D

3D

4D

# of Doors



Do not create a new container code.

10. Expendable Packaging Requirements

a) General guidelines

Expendable packaging should only be used as last option, as it has a negative impact to safety, environment, cost, quality and productivity.

All parts must have minimum of 2 days expendable packaging approved & available by QCS.

Exception to expendable packaging requirements: o Larger parts shipped in racks typically do not utilize expendable packaging as a back-up

shipping method. o Please contact your NAMC Packaging Specialist to clarify requirements. o In the event of a rack shortage where expendable packaging is not available, it is critical

to notify the NAMC Packaging Specialist immediately. Additional time will be required to coordinate alternative shipping methods.

o NOTE: TMMC Does not require pre-authorization for expendable use, if the expendable use and design meet the criteria outlined in the SLIM manual

b) Design guidelines:

Supplier is responsible for design. o Design must ensure part quality from Supplier process, through Toyota Logistics

network and to NAMC part unload.

Expendable packaging must have the same dimensions and QPC as the approved returnable packaging for that part number.

Dunnage should be as similar as possible to approved returnable dunnage. o Wrapping or bagging of individual parts will not be permitted.

Design must be tested, finalized, approved and available by QCS. o Refer to Section 3.2.J for details on approval process. o Must be tested in accordance to ASTM standards, and meet all quality and safety

requirements. o Test report must be available upon request when submitting design for approval.

Use of materials coated or impregnated with wax or polyethylene must have prior approval.

Supplier responsible to repack if expendable packaging design has not been approved and doesn’t meet requirements.

Hand held expendable containers: o Max weight per container, including dunnage and parts: 15kg. o Must have hand holes. o Half Slotted Containers (HSC) with 50mm top flaps must be used. A shoebox style lid

may be used to help stabilize stacking in transit. Regular Slotted Containers (RSC) with full flaps meeting in the center will not be permitted.



Pallet size expendable containers: o Corrugated pallet boxes may be used if part mandates. o The standard size is a 45”x48” pallet, with a maximum height of 50”. o When pallet boxes are attached to the pallet, a breakaway design is required.

c) Kanban holders:

Kanban labels are NOT to be affixed directly to the expendable container.

A clear adhesive pouch is to be used for the Kanban cardholder and applied to the same side as would be for the approved returnable container.

The pouch cannot cover the sealing tape on a container.

The pouch must have an opening on top for easy removal of Kanban card.

d) Handheld container closures

For closures, only non-reinforced paper tape is allowed.

No staples are permitted due to safety and possible part damage. Top flaps:

o Two strips of two inch non-reinforced paper tape are to be used per expendable container to seal top flaps.

o Tape the expendable container across the length of the shortest flaps. This will provide adequate protection to the parts and allow team members at our customer to easily open by hand.

o Do not tape across the corners. This will make it difficult for team members to open by hand.

Bottom flaps: o Boxes 10kg or less should be sealed with one strip of non-reinforced paper tape.

Half Slotted Containers Shoe Box Style Lid Regular Slotted Containers



o Boxes greater than 10kg to be sealed with 2 strips of non-reinforced paper tape required in a cross style to prevent the bottom from opening.

e) Handheld expendable container example:

10kg or Less Greater than 10kg



f) Pallets

If all containers on the pallet load are in expendable containers, ship using a wooden pallet. o If the majority of the containers on the pallet load are returnable containers, utilize a

returnable pallet and top cap if available.

Palletize expendable containers securely on a 45”x48” 4-way wooden pallet and cover with a corrugated top cap.

Boxes must not overhang the base of the pallet. This could result in damaged freight when loading onto the trailer.

Pallets must be constructed to meet the minimum requirement for the load handled.

Nailed construction is required.

Stringer style, non-reversible construction is required with 3.5 in minimum height fork opening.

If shipping wood pallets between Mexico, US or Canada: Customs regulations require that all wood material shipping to / from foreign countries ship on pest treated pallets. Shipper must ensure that all wood pallets used between these countries meet custom regulations. The below image shows the International Plant Protection Convention (IPPC) logo. o Please confirm logo requirements.

g) Top Cap

Top Caps must be made of 200# C Flute Corrugated Board.

Dimension of the assembled Top Cap must fit a full layer of boxes.

For correct Top Cap size, measure one full layer of boxes to confirm inside dimension.

See below example of Top Cap for one full layer boxes.

Top Cap corners should be secured using glue or 2” Non-Reinforced Paper Tape



11. Safety and Ergonomic Standards

a) General requirements

Part removal o Parts should be free of entanglement. o Dunnage should not come loose when parts are removed. o Expendable &/or returnable containers and dunnage should not have sharp edges. o Extraction force should be as low as possible (zero).

Handheld container max weight requirement o 15kg = maximum weight for all NAMC’s. o Max weight may be adjusted based on tote size. The NAMC will adjust as necessary.

b) Specific requirements

Please refer to below guidelines and VPACS documentation for complete guidelines, tables, and formulas. (Also in VPACS documentation).

1151mm(45.3”)

76mm

(3.0”)

76mm (3.0”)

1227mm(48.3”)

Glue or Tape Flaps to form top cap corners

note:

Top Cap example for Standard 48x45

returnable pallet.(Dimensions shown are

inside dimensions without scoring allowance)



linkage linkage

Item Criteria Purpose Design ApplicationShould Not

Exceed Ideal Value Measurement Criteria

Push with thumb

Pushing with thumb where

surface area <30mm2 (approx

area of a finger tip). If a digit

cannot be supported, a limit of

1 kg push is recommended.

The structure of the

finger/thumb tips is not

suitable for absorbing high

contact stresses, which can

result in injury to the nerves,

tendons and ligaments

Where forces exceed guideline

alternatives may be to reduce

the required force or to improve

the grip or surface area so

greater force may be generated

safely.

æ 3 kg < 1 kgf

Measured using a push/pull

gauge or load cell.

Measure should reflect as

closely as possible

production conditions such as

time required to complete &

line of force

Pinch grip (thumb & one or

more fingers or fingers to palm)

Force required to

grip/manipulate/operate an

object/tool held in a pinch grip.

(Item is "pinched" between the

thumb and finger(s))

Pinch grips require 5 times

greater muscular effort than

power type grips. High force

pinch grips can typically

cause injury to the tendons in

the hand, forearm & elbow &

muscle fatigue in the hand &

forearm

Design should consider the

elimination of pinch grips

where it is possible to alter the

hand to part/tool interface to

create a power type grip or by

the use of fixtures or tools

æ 3 kg < 1 kgf


gauge or load cell.


closely as possible



line of force

Push or pull with 2 or

more fingers Push or pull force that must be

generated to complete an

operation where the force can

only be applied using the

fingers/thumb.

The structure of the

finger/thumb tips is not

suitable for absorbing high

contact stresses, which can

result in injury to the nerves,

tendons and ligaments

Design should consider

reducing the required force or

creating an improved handhold

where greater force can be

safely generated or the use of a

tool or fixture.

æ 4kg æ 4kgMeasured using a push/pull

gauge or load cell.

Push or pull with one

handPush force that must be



only be applied using a single

hand. Assumes that the force is

spread over the whole hand

with either a power grip or flat

hand.

Forces applied at the hand

can generate significant

moment arms and loading on

the wrist, elbow and shoulder.

Reducing the forces required

at the hand will protect the

structure of these joints from

injury

Design should consider how

force must be applied. Where

forces/loads may exceed the

recommendations enabling the

use of 2 hands will help

alleviate stress on one arm.

æ 7 kg between

635 (knee) &

1255mm (shoulder)

<6kg if work ht.

<635 (knee) or

>1255mm

(shoulder)

æ 7 kg between

635 (knee) &

1255mm (shoulder)

<4kg if work ht.

<635 (knee) or

>1255mm

(shoulder)


closely as possible



line of force

Push or pull with

both hands or palms

Push force that must be



be applied using both hands.

Assumes that the force is

spread over the whole of the

hands with either a power grip

or flat hand.

Numerical values

corresponding to knee &

shoulder heights are provided

for standing work; otherwise

use knee & shoulder as height

reference pts.

Forces applied at the hand

can generate significant

moment arms and loading on

the wrist, elbow and shoulder.

Reducing the forces required

at the hand will protect the

structure of these joints from

injury

Consideration must be given to

the interface between the

hands and object. Poor grip or

unequal division of the load

between hands can impede

performance.

It is preferable for forces to be

generated between knee and

shoulder heights, where body

weight can also be applied.

æ 10 kgf between

635 (knee) &

1255mm (shoulder)

æ 6kgf if work ht.

<635 (knee) or

>1255mm

(shoulder)

æ 10 kgf between

635 (knee) &

1255mm (shoulder)

æ 6kgf if work ht.

<635 (knee) or

>1255mm

(shoulder)


gauge or load cell.


closely as possible



line of force

Weight of individual

part (One or two

hands)

For parts above 5kg, a

detailed evaluation (NIOSH) of

the lift must be performed

considering height, reach &

frequency.

Manual materials handling is

a major source of risk to the

back and upper limbs and is

the largest cause of lost time

injuries within the US.

Where repetitively lifted

weights exceed 15kg and/or

the NIOSH RWL an assist

device must be used, the

weight of the object reduced or

an operation std to require a

multi-person lift.

æ 5 kg OR

æ 15kg AND

<NIOSH

Recommended

Weight Limit (RWL)

æ 5 kg OR

æ 15kg AND

<NIOSH

Recommended

Weight Limit (RWL)

Establish part/sub assembly

weight.

Use NIOSH Lifting equation

(Attached) to asses the need

for a lift assist device or

changes required to the lift

e.g. reduce reach distance.

Weight of part,

package or box (two hand lift) Lifts are 2 handed with fair

handholds, symmetrical and

close into the body.






When determining packaging,

delivery method and storage

position consideration should

be given to frequency, heights

& reaches in conjunction with

the weight.

æ 15 kg

Sliding scale from

15 Kg max based

on freq. & height

See Table 1

(modified from

original 300N

Ringi)

Establish the weight and

required frequency and

consult with safety group

Push/pull force for

dolly/cart/lift assist

devices

Force required to initiate and

sustain movement of a

dolly/cart or similar where both

hands are in contact and are

between waist and shoulder

height AND force is generated

from the legs.






The level of force required is a

function of the weight of the

object, the size of the wheels

and the resistance between the

wheel and the ground. Using

larger, low friction wheels can

significantly reduce push/pull

forces.

æ 15 kg

initialæ 15kgf initial

æ 10kgf sustained

Measure using a push/pull

gauge or similar device, the

force required firstly to

overcome inertia and second

the force required to maintain

momentum

FO

RC

ES

W

EIG

HT

S



12. Testing Standards

a) Toyota Party utilizes ASTM D4169, Standard Practice for Performance Testing of Shipping Containers and Systems. The details on this standard procedure and others referenced within this section can be

found at www.astm.org.

b) Testing requirement guideline

Min. clearance to

prevent pinch points

for hands & wristDistance between the moving

part(s) and any fixed surfaces

which create a pinch point

Where distances between

surfaces that are moving

together can be made

>100mm, the pinch point

hazard for the hand or wrist is

eliminated and may not

require guarding where further

intrusion into the working zone

is prevented.

Where possible eliminate

pinch points and potentially the

need for guarding by creating

adequate clearance distances

>100mm >100mm

Measured at the minimum

clearance distance between

the convergent surfaces.

Min. clearance to

prevent pinch points

for fingerDistance between the moving

part(s) and any fixed surfaces

which create a pinch point

Where distances between

surfaces that are moving

together can be made >25mm,

the pinch point hazard for

fingers is eliminated and may

not require guarding where

further intrusion into the

working zone is prevented.

Where possible eliminate

pinch points and potentially the

need for guarding by creating

adequate clearance distances

>25mm >25mm

Measured at the minimum

clearance distance between

the convergent surfaces.

Principal Standing

Operating RangeMeasured from the standing

surface to the principal working

position of the hands.

The principal work height

refers to the height at which the

majority of a cycles work is

performed and is based on

typical light to med. assembly

type activity

Heights are based upon elbow

heights of US population &

include a 30mm allowance for

work shoes/boots.

Surfaces that are too high

typically cause the t/m's

elbows to be held away from

the body causing muscular

load on the shoulder.

Surfaces that are too low

cause the t/m to stoop or bend

Work surface heights, line

heights should be determined

so that the t/m's hands are

within the principal working

zone when performing the task.

880mm to

1080mm

Use 880 - 1080mm

for principle work ht

for equipment &

develop

Zones of

Convenient

Reach for

processes

Measured from the standing

work surface to the height of

the hands when performing

the task.

Max Work

Reach (Horizontal)

Measured from hip to the

knuckles at the farthest point of

operation where no edge

OR

Measured from the belt buckle

or front edge of the work

surface/machine to the

knuckles at the farthest point of

operation and use bracketed

numbers [x].

Frequent reach is > 2 per min.

Excessive reaching increases

the muscle loading on the

shoulders and back and

increases the time required to

perform the job element.

For processes done on the

vehicle the designer must

consider where the t/m is

situated to carry out the

operation.

When designing

machinery/workstations

consider the distance from the

front edge to the farthest

required reach.

Max reach

æ 700mm

[æ 635mm]

Recommended

frequent reach

zone

æ 450mm

[æ 380mm

Max reach

æ 700mm

[æ 635mm]

Recommended

frequent reach

zone

æ 450mm

[æ 380mm

Where reach is limited only

by the position of the t/m e.g.

on a Raku seat measure the

distance from either the

center of the shoulder joint or

hip joint depending on the

height of the work, otherwise

from the edge of the machine

and use numbers in brackets

Max Work

Reach (vertical)


surface to the knuckle of the

hand gripping the object.

Criteria developed on the

functional grasp of a 1%'tile

female plus 30mm for work

shoes/boots.

NB This height is below head

height for approx 25% of Male

population

Excessive stretching and

overhead reaches place

increased loading on the

body.

Inability to reach a required

tool or control may impact a

t/m's ability to perform a task.

This height ensures that all US

t/m's will be able to reach &

grip an overhead object. Care

should be exercised where this

may impact head clearance for

taller t/m's

æ 1820mm æ 1820mm


work surface to the height of

the hands when performing

the operation.

Flowrack/

Parts storage heightThe upper limit is measured

from the floor to the shelf. The

height of the lowest shelf is

determined by the height of the

hands when picking.

NB This criteria should be

used in conjunction with W2

when considering layouts

Manual material handling

above shoulder heights is a

major cause of injuries.

Repetitive handling of loads

below 800mm requires

bending/stooping

When planning parts storage

requirements sufficient room

needs to be allowed to keep

shelf heights below

1500mm,and ideally above

635mm (knee height) for

storage and above 800mm for

parts used each Takt cycle.

Max top shelf

1500mm

Advisory lowest

height of 635mm

Min height for parts

used each Takt

cycle 800mm

Max top shelf

1500mm

Advisory lowest

height of 635mm

Min height for parts

used each Takt

cycle 800mm

Upper limit; measure from the

standing surface to the

surface of the upper shelf.

The limit is set to allow the

shelf height plus one box and

assumes gripping at the base

of the object.

The lower limit is measured to

the position of the knuckles

when gripping the object,

This is done to reflect the

impact of object height.

DE

SIG

N O

F

PA

RT

S/P

RO

DU

CT

/EQ

UIP

ME

NT

PO

SU

TU

RE

1820mm

http://www.astm.org/



Test Required

Tote / Knockdown / Bin w/ NO dunnage No

Tote / Knockdown / Bin WITH dunnage No

Rack / Stackable Tray Yes if new & critical part

Tote / Knockdown / Bin w/ NO dunnage No; confirm w/ NAMC

Tote / Knockdown / Bin WITH dunnage Yes

Rack / Stackable Tray Yes

New

Carryover

Packaging

This is a guideline ONLY. If you need clarification on which parts require specific tests, please contact your NAMC Packaging Specialist.

Supplier is responsible for a returnable &/or expendable packaging design that ensures part quality. Testing is used to find potential transit issues.

Part requirement matrix:

Examples of critical vs. non-critical parts:

Packaging requirement matrix:

Process flow:

Testing Required

Critical Yes, if new packaging design

Non-critical No

Critical Yes

Non-critical Refer to packaging matrix

Part

New

Carryover

Part Examples*

Critical

- Class A

- High cost

- Sensitive component

Non-critical

- Non class A

- Low cost

- Robust, non sensitive components

* This is a guideline ONLY; contact NAMC w/ questions.

Supplie

r

Determine if

testing is

required

Check Part

Matrix

Testing

Required

Check Pkg

Matrix

Testing

Required

Move to next

step in Pkg

Development

Test part &

package

Yes Yes

No No



c) Part Availability for Testing Supplier is responsible to have parts dedicated for prototype fabrication, testing and

trials. Part availability for specific packaging development activity is required. Planning for part availability should be included in the vehicle development schedule. NAMC packaging will not reimburse for parts.

d) Determine Assurance Level

Assurance Level II is baseline unless conditions dictate otherwise. o Assurance Level I provides a more severe test than II. o Assurance Level II provides a more severe test than III.

There may be factors within the transportation cycle that require the more severe test of Assurance Level I. o Examples: Rail, international roads, etc. o Contact your NAMC Packaging Specialist if you are uncertain about transit method. o Refer to VPACS documentation for additional testing information.

DO NOT UTILZE ASSURANCE LEVEL III FOR ANY TESTING.

e) Test Attendance Required for inspection and quick countermeasure if problem is found.

o Fabricator: Required. o Supplier: Required. o Toyota Party: As needed.

If Toyota Party representative cannot be present: o Test results must be communicated to Toyota Party immediately after testing. o If there is an issue, Supplier & Fabricator must hold a teleconference with Toyota Party

representative within one business day. o Supplier or Fabricator, (dependent on design role; Refer to Section 3.2.D.1 “Trial

Authorization Shipment”), to provide test results when they are available. f) Test Plan

Required tests are based on ASTM D4169, Standard Practice for Performance Testing of Shipping Containers & Systems.



Supplier is responsible to confirm part and packaging quality prior to and after testing.

g) Approval Supplier responsible to confirm packaging design passes all required tests. If container does not pass any/all tests, modify/kaizen design until it passes all.

13. Hazmat Compliance

a) All Suppliers that ship material classified as hazardous must comply with the guidelines and

compliance requirements defined in chapter 6 of SLIM, “Hazmat Compliance”.

b) This section of the SLIM manual does not provide instruction for Hazmat packing and

shipping requirements.

c) For tracking purposes only, if you are shipping a hazmat part, please select ‘yes’ on the PPF.

14. Returnable Packaging Transportation Process

Test Type Picture ASTM Method

Random

Vibration

Refer to:

ASTM D4728

Oscillitory

VibrationRefer to:

ASTM D999

Incline ImpactRefer to:

ASTM D880

Drop TestingRefer to:

ASTM 5276Drop Testing

Center of Gravity

Side Surface Drop

Flat Bottom

Drop

Drop Testing



This refers to the following: All returnable packaging related movement between NAMC, Supplier, Fabricator and

testing facility. New and current returnable packaging repair, design change or retrofit.

a) Process for all NAMC's EXCEPT TMMC:

Supplier or Fabricator (dependent on receipt of Authorization; refer to Section 3.2.D) will set up transportation.

Obtain at least 2 quotes from Logistics Providers (LP). Choose the most cost effective carrier and coordinate the pick-up/delivery. Add transportation cost to quote when submitting to TEMA PUR.

b) Process for TMMC:

Approved Fabricators to arrange freight movement with pre-approved Logistics Partner (LP).

Suppliers to arrange freight movement with pre-approved LP. TMMC will be advised and billed directly for all freight movement by the LP's. Freight movement 70lbs (32kg) or under:

o Arrangement of returnable packaging movement is to be made with: Fed-Ex in the US. Purolator Courier within Canada.

o Please contact the TMMC Packaging Specialist for the account number to charge. Freight movement greater than 70lbs (32kg):

o Please arrange returnable packaging movement with Challenger Motor Freight. o Transmitting Advanced Shipment Notification (ASN) to Challenger Motor Freight:

48 hours prior to shipment date Phone: 1-800-268-2096 Ext. 2300 Fax: (519) 653-0858 Email: [email protected]

o Challenger will acknowledge your request within 24 hours and make scheduling arrangements with shipper and receiver for trucks.

Example: See Appendix for Challenger ASN for TMMC transportation Example: See Appendix for Challenger BOL for TMMC transportation

I. Packaging Purchase Process

1. This section applies to ALL NAMC’s EXCEPT TMMC: a) Background

Supplier will need a delegated systems administrator who is responsible to set up necessary access ‘rights’ to Toyota Party internet software for Supplier’s representatives. Delivery issues are often the result of insufficient rights at the company representative level.

b) Commonly Used Software



www.ToyotaSupplier.com: Portal through which other sites are accessed. ePO tab: Site accessible within ToyotaSupplier.com where returnable packaging PO’s are

dispatched; this site retains the PO’s until picked up or until timed out (45 days after dispatch).

VPACS: Refer to Section 3.1 for additional information. EIPP: Enables electronic invoicing against Toyota Party PO’s and speeds up payment

process. WARP: Software for communication between Supplier, Fabricator and TEMA Purchasing.

o TEMA Purchasing will trigger a Request for Quote (RFQ) in response to an Authorization in VPACS.

o Suppliers then quote their costs (the result of which is a PO dispatched to ePO tab that the Supplier can invoice, or if enrolled in EIPP, Supplier can access PO in EIPP).

o A tutorial on how to navigate this software is located on ToyotaSupplier.com Go to: My Applications -> WARP Interface -> Help (link on top right of screen).

c) Procurement Authorization

Returnable Container Authorization (“RCA” or “Auth”) is a directive from Toyota to the issued party directing a procurement activity of returnable packaging on behalf of Toyota.

Noted on the bottom of the RCA is the following instruction: o Procure order within 5 days of receiving authorization. o With this authorization, Toyota Party agrees to reimburse costs for the approved

quantities of containers that are design compliant, reasonable, and verifiable. Design compliant is defined as complying with Toyota Party documented

specifications as recorded in SLIM, the Packaging Proposal, any other Toyota Party directives on file under documentation within VPACS and quantities as identified on this authorization. Production tooling is reimbursed on the first production order.

Reasonable is defined as: i) being the most competitive rate between at least two sources unless mitigating circumstances prevail which are concurred to by Toyota Party in advance; ii) competitive versus previously approved packaging; and/or iii) based on cost standards.

Verifiable is defined as supportable by Fabricator quotations and/or invoices upon request or, as in the case of freight, by past performance history.

o Supplier's invoice must be submitted with a copy of source's packing slip or the like proof of receipt of goods. It should be signed by Supplier as having inspected product for confirmation to packaging specifications, for reimbursement. Supplier’s invoice must reference Toyota Party’s PO number, which will be issued upon acceptance of Supplier’s quotation in WARP.

o Supplier agrees that this Returnable Container Authorization is a Contract Document as defined in the Toyota Motor Engineering & Manufacturing North America, Inc. (“TEMA”) Terms and Conditions located under the Suppliers Guide at www.toyotasupplier.com(the “Terms and Conditions”), all of which are incorporated herein by reference as part of this Returnable Container Authorization. Any additional terms proposed by Supplier are not applicable unless accepted by TEMA in writing

Types of Returnable Container Authorizations:

o Prototype: Enables reimbursement of all aspects related to development and specification approval of one returnable package.



Includes engineering design, dunnage, Kanban holders, labels, prototype tooling, testing (if required by NAMC), freight costs between Fabricator, testing facility, Supplier and NAMC.

Not included would be a pallet or lid, production tooling, vehicle parts, SG&A or profit.

The PPF should be updated before quoting RFQ in WARP if the returnable package specification has changed in the course of engineering/design efforts. Price variance will be justified by reference to the specification of PPF at time of quotation review/PO issuance.

o Production: Quantity of various returnable packaging types (container, pallet, lid, dunnage, etc.) is determined by the NAMC and approved by TEMA Purchasing. Assumes procurement within 5 days of receipt of authorization. Assumes competitively bid between at least 2 sources unless mitigating

circumstances prevail (such as the Toyota Party directing sole source or additional quantity order where original order involved tooling and current rates are close to previous rates).

o Container repair / replacement: NAMC will issue an Authorization for repair/ replacement. Even if the NAMC initiates as a lot of 1, TEMA PUR requires the Supplier to include

both quantity of returnable packaging affected and nature of remedy performed (i.e. re-welded connections, replaced hinges, lowered brackets, etc.) when submitting quote.

o Prototype RCA routing: Steel containers: Authorizations are routed directly to the Fabricator; Supplier is

copied for tracking capability. All plastic containers (standard and nonstandard) are routed directly to the Supplier.

o Production and repair/replacement RCA routing: Steel containers: Authorizations are routed directly to the Fabricator; Supplier is

copied for tracking capability. Standard plastic containers with NO DUNNAGE: Authorizations are routed directly

to the Fabricator as assigned by Supplier on the PPF. Nonstandard plastic container or standard plastic container WITH DUNNAGE:

Authorizations routed to Supplier.

# Returnable Container Type RCA To RCA CC'd

1 - Steel: All returnable containers Fabricator Supplier

2 - Plastic: All returnable containers Supplier n/a



Expendable packaging reimbursement: If returnable packaging is not available to make shipments, Supplier makes request to NAMC to use expendable packaging. o Returnable packaging shortage process: Refer to Section 3.3.B. o Responsibilities:

Supplier: identify occasion, quantity used, rate and backup document supporting rates quoted.

NAMC Packaging: approve use, confirm quantity and confirm responsibility. TEMA Purchasing: approve rates and issue PO.

o If Toyota Party is determined to be responsible for the shortage: NAMC Packaging will issue an RCA in VPACS. TEMA PUR will review unit rate. If approved, TEMA PUR will issue RCA and PO.

o If Supplier is determined to be responsible for the shortage: Supplier to cover associated costs. If further explanation is required, please follow up with NAMC Packaging.

o If the Supplier doesn’t receive a PO within a month of RCA approval, Supplier should: Check VPACS to confirm whether it was deemed NAMC or Supplier responsibility. If NAMC responsibility, contact TEMA Purchasing to inquire on status.

Communication to TEMA Purchasing - Always provide RCA number.

d) Quoting process if RCA is issue to Supplier.

WARP:

o The Supplier or Fabricator should quote costs in WARP against the appropriate RFQ.

o An RCA issued in VPACS should generate an RFQ in WARP.

o If no RFQ appears in WARP after a few days, the Supplier/ Fabricator should contact TEMA Purchasing to alert them of issue (provide RCA number in communication).

Quotation key points:

o Toyota has established rates with Orbis and Schaefer for standard sized totes, pallets, lids and knockdowns. The expectation is for the Supplier to request bids from both Fabricators and select the more competitive source, unless mitigating circumstances prevail and are agreed to by Toyota in advance. If the standard totes, pallets, lids and knockdowns are purchased through a third party, Toyota will only reimburse at the standard rates established with Orbis and Schaefer.

o Kanban holder and label items are assumed authorized even if omitted from the RCA because this accords to the returnable packaging specifications.

o Dunnage is not assumed and quantity must be recorded on the RCA since this varies per part number.

o Production tooling should be quoted on first production order or it will not be approved, unless new source selected due to overall cost savings.

o Additions will generally be denied; such as Supplier’s internal requirement of additional labels.

# Returnable Container Type RCA To RCA CC'd

1- Steel: All returnable containers

- Plastic: All standard returnable containers with NO dunnage.Fabricator Supplier

2- Plastic: All standard returnable containers WITH dunnage &

all non standard returnable containers with or without dunnage.Supplier n/a



Allowable exceptions, if the PPF on file in VPACS specifies a tote lid on the container line comment field or if the ‘Dunnage 2’ or ‘Other’ lines are utilized to define returnable &/or expendable packaging specifications, then the Supplier needs to add these items to their quotation of the RFQ in WARP since the interface between VPACS and WARP does not automatically transmit this information.

o Markup fees are always denied (Selling, General, and Administrative Expenses, and Profit are provided for as a category on the vehicle part pricing).

o Do not enter a dollar amount in the authorization line.

o Artwork (for initial coding setup for the information printed on labels) should only appear the first time a container is ordered for a new supplier plant code or if a Fabricator is being used for the first time.

Internal use label cost should be at the Supplier’s expense and not claimed.

o Freight costs between Fabricator and Supplier can be quoted at cost or be estimated.

Quoting at cost delays the Supplier/Fabricator ability to quote until shipment is received.

If estimating, it should be based on previous experience or third party quotation.

Shipping points, origin and destination zip codes, should be included in comments.

o Tax costs are determined based on Supplier’s plant location since Supplier owns packaging.

o Toyota Party understands the items being quoted in WARP are not classically freight or tax; rather they represent reimbursement lines of costs the Supplier/Fabricator has incurred.

The ‘Ship To’ address on the PO is a Toyota Party location but the freight cost quoted is an acquisition cost of packaging from Fabricator to Supplier to be available for shipping vehicle parts to Toyota Party.

The tax line, if quoted, is the cost Fabricator/source has charged Supplier and is assessing based on Supplier’s location; Fabricator/source is collecting funds to submit to state taxing entity. To the Toyota Party this represents a packaging cost, not tax. (Supplier is not collecting funds to send to a state taxing entity based on Toyota Party location) Toyota Party PO’s will declare they are Tax Exempt.

o Supplier cannot add freight or tax to PO amount after PO has been issued. All items of cost need to be negotiated in advance through WARP before PO has been issued.

o While WARP color codes Supplier response time to RFQ's triggered (turning from green to red after 2 weeks), Supplier response time for returnable packaging RFQ’s are not evaluated.

After 2 months, TEMA Purchasing will send an expediting email to the WARP contacts of record (Supplier maintained) requesting either email response for more time or RFQ quotation.

Supplier failure to respond results in RFQ deletion.

To retrigger an RFQ, the Supplier needs to email a retrigger request to TEMA Purchasing (provide RCA in communication).

e) Quoting process if RCA is issued to Fabricator.

Steel prototype orders



o Paid at a fixed rate per complexity level. If complexity level has been estimated or initially quoted by both NAMC and Fabricator at a different level than resulting design, a rate change can be requested.

o The fixed rate includes all freight, tests, engineer design, and a final approved rack.

o It also includes a copy of production level drawing sent to TEMA (details in the drawing section of the North American standards section 3.0.H.7.f).

o Quotes should be responded to within 2 weeks of receipt.

Steel mass production orders

o Quoted outside of WARP using the TEMA standard quotation sheet.

o The following items must be included with the final quotation: design change tracking sheet (if changes are required) and final PDF drawing.

o Quotes should be responded to within 2 weeks of receipt.

Plastic mass production orders

o Includes standard plastic containers with no dunnage.

o TEMA PUR will issue a PO outside of WARP upon receipt of Orbis and Schaefer weekly claim submission.

f) PO issuance

RFQ’s submitted in WARP should be responded to within 2 weeks.

o If quotation is rejected, Supplier should read the rejection comments and respond accordingly before resubmitting.

o If quotation is accepted, a PO should be dispatched to ePO tab of ToyotaSupplier.com.

If Supplier/Fabricator discovers an RCA that they have not received a PO or payment for, the Supplier/Fabricator should request status information from TEMA Purchasing (provide RCA number in communication).

g) Invoicing

Supplier/Fabricator invoice should reference the Toyota Party PO number, as TEMA Accounting & Finance (A&F) does not recognize RCA number, part number or RFQ number.

Attached to Supplier/Fabricator invoice (including EIPP invoices) must be a 3rd party generated proof of receipt (such as a copy of a packing slip from Fabricator/source to Supplier, an invoice from Fabricator/source or an email from NAMC Packaging originator who attests to/witnessed goods/services received).

Invoice may not exceed value declared on PO.

o If the Supplier/Fabricator discovers their quote was incorrect (wrong rates or omitted components) after PO has been issued, Toyota Party is not under any obligation to review or reopen the RCA/PO.

o If invoice is rejected, there should be an invoice rejection comment stating the reason for the rejection. If there is no message or the message is not understood, please contact Karen Rath - [email protected] with PO#, Invoice #, and invoice date for clarification.

mailto:[email protected]



Responsibility Target Timing

Key: N= Month of SOP

NAMC PC N-15

NAMC PC N-14

Supplier N-10

NAMC PC N-10

NAMC PC N-10

TEMA Pur N-10

N-10

Supplier N-8

NAMC PC N-7

Supplier N-6

TEMA Pur N-6

NAMC PC N-6

NAMC PC N-6

TEMA Pur N-6

TEMA Pur N-6

Fabricator/Supplier N-6

Supplier N-5


Fabricator N-5

TEMA Pur N-5


Returnable Packaging Design & Procurement Process Returnable Packaging Reimbursement Process

Supplier / Rack

Fabricator

Approve Quote

accept

no

accept with trial

reject

Begins Process- part list- prelim proposal pkg type per part #

Sends Preliminary Packaging Proposal to Supplier in VPACS

Sends Prelim Packaging Proposal back to NAMC PC in VPACS

Review Proposal

Initiates Authorization Prototype in VPACS

Approves Authorization Prototype in VPACS

Acquires and Ships Prototype

Review s Prototype

Sends Final Packaging Proposal back to NAMC PC in VPACS

accept with no trial

Supplier Contacts NAMC Pkg

reject

accept

Triggers RFQ in WARP

Quotes RFQ in WARP

Reviews Proposal

Approve Quote

Triggers RFQ in WARP

Quotes RFQ in WARP

see PO/pymt process below

yes

Receives Authorization in VPACS

Fabricator Receives Authorization in VPACS

reject

Supplier Contacts NAMC Pkg Specialist

Supplier Forecasts receipt date in VPACS

Receives RFQ in WARP

Receives RFQ in WARP

Fabricator Quotes to Toyota

Approve Quote

Routes Authorization to Supplier

No, No further action

Yes, Initiates Production

Authorization

Supplier Receives Authorization in VPACS

see PO/pymt process below

yes

no

copy

no

yes

Stock Required?

Steel or standard plastic w / No

dunnage?

Supplier Orders Packaging

Select fabricator & route Authorization directly to fabricator; cc Supplier

no

Fabricator Forecasts ship date in VPACS

h) TEMA Purchasing Process Flow



2. This section applies to TMMC Only:

a) New model returnable packaging:

Purchase orders will be issued directly to Fabricators from TMMC. VPACS authorizations (RCA’s) are not currently part of TMMC process.

b) Expendable packaging, returnable packaging repair and/or replacement

Packaging claims o Provide Suppliers with the procedures to recover costs for expendable &/or returnable

packaging. o Claims are to be submitted to TMMC Packaging by the 10th of the following month for

the costs incurred in the previous month. o The Supplier is authorized to proceed with any repair claim less than $5000 CDN. The

Supplier must verify to TMMC Packaging that materials/services are complete prior to invoicing.

Claims submission process flow (Also in VPACS Documentation):

Responsibility Target Timing General Flow Responsibility Target Timing

quote

TEMA PC wk 1

TEMA Pur wk 1

TEMA A&F wk 2

Supplier/

Fabricatorwk 2

Supplier/

Fabricator

EIPP terms or

net 25 prox

Returnable Packaging PO Process Returnable Packaging Payment Process

General Flow

Supplier/

Fabricator

Supplier/

Fabricator

packaging

deliveredSubmits Quote

noApprove

Quote

yes

Receives PO in EIPP or dispatched to ePO tab of

ToyotaSupplier.com

Sends Invoice to TEMA with proof of receipt

Confirms Receipt

Schedules Payment

Receives Wire Transfer Payment

from TEMA



TMMC Packaging claim cover sheet (Also in VPACS Documentation):



3. Self-Procured (SP), Controlled Self-Procured (CSP) and Direct Supply (DS) Tier II Packaging

Packaging required for any Tier II packaging is NOT included within Toyota North American Packaging activity. Refer to Section 3.0.K.

Please contact your Toyota Parts Purchasing Specialist for detailed support.

High level roles & responsibilities:

NOTE: “Packaging cost” refers to initial purchase and also ongoing repair and maintenance.

J. Returnable Packaging Ownership

1. Returnable packaging is the property of the Supplier; with the exception of TMMC. (TMMC owns their returnable packaging.)

2. Toyota Party’s policy regarding returnable packaging ownership is outlined in the Terms at Section 2.4(d)(1).

Who SP (Self-Procured) CSP (Controlled Self-Procured) DS (Direct Supply)

Tier II

Purchase & Design Packaging to

ensure integrity of parts or materials

during transit. The packaging may be

returnable or expendable.









Tier I Approve packaging designed by the

Tier II supplier.

Approve packaging designed by the

Tier II supplier.

Approve packaging designed by the

Tier II supplier.

Toyota Parts

Purchasing

Negotiates purchase price (including

packaging cost) of Level I components

with Tier I.



with Tier II.

Will be the intermediary for

commercial issues between the Tier I

and Tier II.



with Tier II.

Will be the intermediary for

commercial issues between the Tier I

and Tier II.

Toyota

PackagingNot involved in this activity. Not involved in this activity. Not involved in this activity.



K. Packaging Quantity Allocation Visualization

1. Toyota Party is responsible to: a) Calculate and purchase the quantity of returnable packaging required to support the Toyota

logistics network. This will include additional pallet & container quantities to account for partial pallet ordering.

b) Recalculate monthly to check for any changes to Logistics lead time, volume fluctuation, route changes, etc.

2. Supplier internal system days allocation is based on pick up frequency. The below matrix is to be used as a GUIDELINE ONLY. The NAMC Packaging specialist will determine ACTUAL quantity.

3. Supplier is responsible to ensure returnable packaging utilized outside the Toyota logistics network is: o Available to support any internal or offsite shipping requirements. (See above visual, also in

Appendix). For Tier II roles & responsibilities, refer to Sec. 3.0.I.3.

o Maintained, repaired and replaced if lost or damaged.

#


Procurement

Responsibility Location in Network Returnable Packaging Quantity Allocation Explanation

Loop between Supplier FOB point and

any off site non-Toyota facility.

ex) Manufacture location, Tier II,

Warehouse, etc.

Supplier 100% responsible to purchase any necessary

requirements.

Internal Work in Process, Inventory

build up / batch production, bank

build, holiday or plant shut down

differences, etc


requirements.

Direct Supply Tier II(Toyota Parts

Purchasing)

Loop between Supplier and Direct

Supply Tier II.

Direct Supply Tier II to purchase any necessary

requirements. Toyota Parts Purchasing will reimburse to

Tier II through piece price.

Supplier internal requirement to

support Toyota shipment.

Example Calculation:

# Day(s) Full + # Day(s) Empty + # Buffer Day(s)

-> Total # days allocated from Toyota for Suppier internal process.

*Exact quantity dependent on multiple factors such as pick up &

delivery frequency. NAMC will calculate & provide detail quantity

allocation.

Transit time between Supplier and

Toyota NAMC

# Days in transit from:

Supplier to NAMC, including time in cross dock, yard, etc.


NAMC to Supplier, including time in cross dock, yard, etc.

Buffer:

# Days Supplier to NAMC + # Days NAMC to Supplier + Buffer

-> Total # days allocated for transit time.

NAMC internal requirement to support

manufacturing process



-> Total # days allocated for NAMC internal process.


delivery frequency. NAMC will calculate detail quantity allocation.

NAMC Packaging

Supplier

1

4

3

2

5

6



KEY POINT: Returnable packaging that is allocated by the Toyota Party is NOT to be utilized outside of the Toyota Logistics Network.

L. Shortage Investigation & Reimbursement

NOTE: This process is currently being made common between all NAMC’s. The change is dependent on a major upgrade to VPACS. Short Term Policy defined below.

1. Process flow for all NAMC’s EXCEPT TMMC. Follow expendable packaging usage tracking and reimbursement process as defined in 3.3.B. The process flow example shown below can be found full size in the Appendix along with the “Investigation Sheet”. (Also in Appendix).

2. Process flow for TMMC: Follow expendable packaging usage tracking and reimbursement process as defined for TMMC in Section 3.3.C. The process flow example shown below can be found full size in the Appendix along with the “Investigation Sheet”. (Also in Appendix).

Returnable Packaging Shortage Investigation & Reimbursement Process: APPLIES TO TMMC ONLY

TMM

C P

acka

ging

Mat

eria

ls

Con

veya

nce

Logi

stic

sM

ater

ials

Ord

erin

gS

uppl

ier

Packaging

Allocation

Confirmation

Supplier

Excess?Yes

Contact Supplier to

explain standards and

to resolve abnormality

Packaging

Underallocated?

No

Instruct Supplier to track


inventory and expendable

packaging tracking for

minimum of 2 weeks

YesLog investigation

results and close

Returnable

Packaging Order

& Procurement

No

Begin an Inventory/

Process Abnormality

Investigation

No

Submit Shortage

Investigation &

Notification Form

to PC Packaging

Log Shortage in

Production

Concern Tracking

Confirmed shortage of


inventory for greater than 2

weeks with no permanent

countermeasure

Alternate Packaging

Available for Supplier

Shipments?

Review with PC Management

investigation results and most

cost effective short term

countermeasure to maintain

production

No

Yes

Communicate to

Supplier timing of


inventory recovery to

relieve shortage

condition

No

Packaging

Claim?

Shortage

Resolved?EndYes

Returnable Packaging Inventory & Expendable Packaging Tracking

Packaging

Claim

Issue DPR for Corrective

Action &

Countermeasure

Complete and

return to TMMC Pkg

Yes

No

Inventory/Process

Abnormality Check

Inventory/Process

Abnormality Check

Inventory/Process

Abnormality Check

Provide Packaging

Specialist details

of countermeasure

and timing to get

back to standard

process/inventory

levels

Abnormality Found?

I.e. scrap reorder, actual order > actual

requirements and/or production, QPC

discrepancy, inventory overflow

Abnormality Found?

I.e. 1 for 1 return, container ID incorrect

Abnormality Found?

I.e. excess inventory at Cross Dock / Yard,

returns at wrong Cross Dock location

Yes

Yes

Yes

No

No

Start

2 weeks 2 days2 days



M. Supplier Issue Resolution Process

1. Purpose is to provide Supplier a method to escalate packaging concern items to obtain resolution. (Document provided in VPACS Documentation).

a) Escalate issues within NAMC Pkg. If no resolution, escalate to TEMA Pkg. b) Requirements: o Both phone call and email are required. When sending email, it is necessary to address only

one NAMC and only one person at that NAMC. o Provide the following data: Supplier name, 5 digit code, PN you are referring, issue and rank.

(Place this data in subject line of emails). If the issue is a returnable container shortage, include “Shortage Investigation Sheet”.

See below for ranking and response time.

See below for contact level and information required at each step.

2. High level process flow

Issue Rank Max Response Time Example

Safety S 1 Day Sharp dunnage edges, parts falling out of container due to container damage issue,etc.

Impact to Parts Shipment A 1 Day Rack shortage w/ no expendable packaging (back-up) available, etc.

Possible Impact to Parts Shipment E 2 Day Returnable packaging shortage w/ expendable packaging (back-up) in use

No Impact to Parts Shipment B 5 Day

Returnable packaging shortage w/ expendable packaging (back-up) available, excess

container, reimbursement follow up, etc.

Contact Level @ Supplier Working Level Working Level Supervisor / Manager Manager or above

Contact Level @ Toyota Specialist Assistant Manager (A/M) Manager General Manager

Information

Required

Via email and phone:- Supplier Name

- Supplier Code

- Issue Type

- Part number

- Issue Rank


- Supplier Code

- Issue Type

- Part number

- Issue Rank

Forward email that was

sent to the Specialist.

Address A/M with same request.


- Supplier Code

- Issue Type

- Part number

- Issue Rank

Forward email that was

sent to the Specialist & A/M

Address Mgr with same request.


- Supplier Code

- Issue Type

- Part number

- Issue Rank

Forward email that was sent to

the Specialst, A/M & Mgr.

Address GM with same request.

Supplier

Raises

Concern /

Issue

NAMC Packaging

SpecialistAssistant

ManagerManager

General

Manager

TEMA Packaging

SpecialistAssistant

ManagerManager

General

Manager

If no resolution,

Supplier escalate

to TEMA Pkg



3. Detail process flow

TE

MA

Pkg

NA

MC

Pkg

Su

pp

lier

Rank S or A: 1 Day; Rank E: 2 Day;

Rank B: 5 Days


Rank B: 5 Days


Rank B: 5 Days


Rank B: 5 Days


Rank B: 5 Days


Rank B: 5 Days


Rank B: 5 Days


Rank B: 5 Days

Supplier Issue Resolution Process

Notify

NAMC pkg

Specialist

of

packaging

related

concern or

issue.

Receive

Response

Receive

Response

Notify

NAMC pkg

Assistant

Manager of

packaging

related

concern or

issue.

Yes Yes

No No

Notify

NAMC pkg

Manager of

packaging

related

concern or

issue.

Yes

No

NAMC Pkg

Manager

Receive

notification

from

Supplier

Notify

NAMC pkg

General

Manager of

packaging

related

concern or

issue.

NAMC Pkg

General

Manager

Receive

notification

from

Supplier

Yes

Yes Yes

NoNo

Yes

No

TEMA Pkg

Manager

Receive

notification

from

Supplier

Notify

TEMA pkg

Assistant

Manager of

packaging

related

concern or

issue.

TEMA Pkg

Assistant

Manager

Receive

notification

from

Supplier

TEMA Pkg

General

Manager

Receive

notification

from

Supplier

TEMA Pkg

Specialist

Receive

notification

from

Supplier

Notify

TEMA pkg

Manager of

packaging

related

concern or

issue.

Notify

TEMA pkg

Specialist

of

packaging

related

concern or

issue.

No

Notify

TEMA pkg

General

Manager of

packaging

related

concern or

issue.

Receive

Response

Receive

Response

Receive

Response

Receive

Response

Receive

Response

Provide

timing &

next steps

to resolve

issue

Provide

timing &

next steps

to resolve

issue

Provide

timing &

next steps

to resolve

issue

Provide

timing &

next steps

to resolve

issue

Provide

timing &

next steps

to resolve

issue

Provide

timing &

next steps

to resolve

issue

Provide

timing &

next steps

to resolve

issue

NAMC Pkg

Specialist

Receive

notification

from

Supplier

NAMC Pkg

Assistant

Manager

Receive

notification

from

Supplier

Provide

timing &

next steps

to resolve

issue

4. Packaging contacts:

The NAMC & TEMA Packaging contact list is provided in VPACS Documentation page. Please check frequently for updates.

5. If no resolution after following and completing above process, provide documentation of each

communication attempt to your parts buyer.



1. VPACS OVERVIEW

A. VPACS Registration

1. ToyotaSupplier.com a) If you do not have access to ToyotaSupplier.com:

Contact the ToyotaSupplier.com Administrator at your facility.

Request access to ToyotaSupplier.com and VPACS application.

TEMA and/or Supplier Administrator will contact you with access rights, Username and passwords.

Log-in to VPACS.

b) If you do have access to ToyotaSupplier.com

Contact the ToyotaSupplier.com Administrator at your facility.

Request access to VPACS application.

TEMA and/or Supplier Administrator will contact you with access rights, Username and passwords.

Log-in to VPACS.

c) Troubleshooting

If you do not know the ToyotaSupplier.com Administrator at your facility: o Contact the Toyota helpdesk for assistance in identifying your Administrator.

If your ToyotaSupplier.com Administrator does not know how to grant/request you access to VPACS: o The Supplier Administrator needs to contact the Toyota Helpdesk for assistance.

2. ToyotaSupplier.com and VPACS support a) System issues, registration information

Toyota Helpdesk: (859.746.HELP) b) General VPACS questions

Email: [email protected]

B. VPACS - Adjust User Settings

1. Everyone will initially receive ‘Read Only’ access level. 2. To receive ‘Write and Submit’ access levels by plant:

a) Supplier Administrator can change each user level by using the ‘Authority List’ link located inside VPACS.

b) If you do not see ‘Authority List’ as a selection option, you do not have access to perform these tasks.

3. To Change settings, follow the steps in VPACS Supplier Training Manual Section 1C.



C. VPACS Tracking Screen Details

1. Toyota Party utilizes the “Documentation” screen to post important information and communications.

2. You can download documents from this screen.



2. PACKAGING DEVELOPMENT

A. High Level Schedule with Milestones

(also in Appendix and VPACS documentation section)

B. Project Kick Off

1. New model information will be provided to Suppliers by NAMC Packaging Specialists via email and the VPACS documentation page.

2. Information to include: a) Notification of project start. b) Overall development schedule with key milestones.

North American Packaging Development High Level ScheduleN-36 N-35 N-34 N-33 N-32 N-31 N-30 N-29 N-28 N-27 N-26 N-25 N-24 N-23 N-22 N-21 N-20 N-19 N-18 N-17 N-16 N-15 N-14 N-13 N-12 N-11 N-10 N-9 N-8 N-7 N-6 N-5 N-4 N-3 N-2 N-1 SOP N+1 N+2 N+3

PROJECT

VEHICLE

MILESTONES

Reference

N-6

NAMC

SUPPLIER Supplier ship to NAMC

NAMC

Begin 5 days after receiving Auth; Refer to Sec. 3.0.I for Purchasing process.

SUPPLIER

N-10

Final PPF approval process

Receive, review & approve/reject N-13 N-6 Step 7

NAMC

NAMC

N-16 N-10

N-16 N-13

Supplier submit Final-PPF in V-PACS


Supplier / Fab begin procurement

NAMC

If reject; Supplier / Fabricator create changes & repeat V-PACS steps 5-7.

N-13 N-10 Step 6

Packaging authorization

Packaging readiness

Actual readiness

Forecast readiness

Previous model Pkg disposition

1st piece ship verification

Budget tracking

Step 3 Supplier submit standard & cost efficient design if no BM design provided.

NAMC N-16 N-10 Step 4 NAMC may approve, reject and/or request changes to proposal.

Send Pre-PPF to Supplier

CommentsV-PACS Step

N-18Advanced Concept (AC) development

NAMC Upload new part list into V-PACS

N-16 N-10

AC confirmation

Pre-PPF approval process

Prototype authorization

NAMC

N-13 N-6

N-18 N-18

N-18 N-18

N-17 N-15

N-10 N-6

N-10 N-6

N-10 N-6

N-10 N-8

N-10 N-6

N-3 N+2

N-15 N+3

N-10 N-3

N-6 N+3

N-10 N-3

Trial approval process

Supplier submit Pre-PPF in V-PACS


Responsibility

TEMA / NAMC

NAMC

TEMA / NAMC

Milestone Name

Advanced planning digital assembly activity

New model budget creation

SUPPLIER

TEMA / NAMC

SUPPLIER

NAMC

SUPPLIER

SUPPLIER

SUPPLIER

NAMC

NAMC

NAMC

FinishStart

N-36 N-18

N-32 N-16

N-27

SUPPLIER

Develop & gain consensus on Benchmark (BM) design for high cost parts.

Step 5 Supplier / Fabricator create prototype, test and review at Supplier facility.

Step 1 Will upload as soon as available; often delayed.

Step 2 Will send BM proposal if developed in AC development.

Supplier confirm if AC BM design is ok.

Step 11 Enter FORECAST readiness date based on Fabricator schedule.

Step 10

Step 8 Supplier to confirm ALL data in PPF is correct.

Step 9 NAMC may reject and/or request changes to proposal.

NAMC confirm packaging specs at first shipment receipt.

NAMC / TEMA will provide disposition on obsolete pkg; Refer to Sec. 3.3.K.

Step 12 Enter ACTUAL date packaging is received at Supplier facility.

Previous Model Packaging Disposition

VSP AS K4 SE Genzu CF 1W

1A

2W

2A SOP

Advanced Planning (AP) Digital Assembly Activity

Advanced Concept (AC) Development AC Confirmation

Pre PPF Approval

New Model Budget Creation / Pkg Qty Calculation

Proto Authorization

Trial Approval Process

Final PPF Approval

Pkg Authorization

Budget Tracking

Packaging Readiness

1st Pc Ship Verification

QCS / LOPart List release & upload /

D

E

A

B

C F

G

H

I

J

K

L

M

O

N

D

E

A

B

C

F

G

H

I

J

K

L

M

O

N



3. The new model parts list will be loaded into VPACS by the NAMC Packaging Specialist.

C. Pre Packaging Proposal Form Completion and Approval

Toyota Party Responsibilities

Decide PPF design roles

Send PPF

Supplier Responsibilities

Understand design role. Pre-PPF completion Dual design PPF completion

Fabricator Responsibilities

Understand design role

Pre-PPF completion

Dual design PPF completion

1. Toyota Party will send Pre PPF to Supplier or Fabricator to complete.

a) Understand design role. Before sending Pre-PPF to Supplier and/or Fabricator for completion, NAMC packaging specialist

will determine PPF design role from one of three options.

o VPACS design role options:

o VPACS design role responsibilities:

Supplier Container Fabricator Dunnage Fabricator

Option 1 Work No Action No Action

Option 2 Confirm Work No Action

Option 3 Confirm No Action Work

RoleRole

Matrix

A

B

C

A

D

E

Initial Packaging Proposal Phase

M-14 ~ M-11

TOYOTA

(NAMC/TEMA)

TIER 1 SUPPLIER

PKG

FABRICATOR

ROLE

Pre-PPF

Completion

Pre-PPF

Completion

View, Approve, or

Reject, PPF from

Pkg Fab

View, Approve, or

Reject, PPF from

Supplier

Pre-PPF

ReviewDual

Design

Tier 1 Pkg

Fab Tier 1

Lead

Fab

Lead

Pre-PPF

Completion

Pre-PPF

Completion

Decide Design

Method

Send Pre-

PPF

Reject

Approve

Trial

Needed

No Trial

Needed

A

B

C

B

D

D

E



b) Determine design role:

The Fabricator name will appear for each PPF with design role option 1,2,4,5,6.

The Fabricator name will not appear for a PPF with design role option 3. o If no Fabricator is designated, PPF completion is Supplier responsibility.

Design role for each PPF can be determined by looking at the tracking screen.

2. Expectation of design:

Design preparation Supplier responsible to have part drawing math data available for design requirements.

Design guidelines o Reuse obsolete or extra packaging if available & applicable. o Utilize smallest standard returnable packaging size that will accommodate part design. o Design/ Redesign packaging to reduce cost, while meeting all applicable legal standards. o Some items to consider are:

Eliminate or reduce dunnage. Use low cost materials. Increase box efficiency. Simplify the design for ease of manufacture. Utilize same design for each NAMC if possible.

Option 1

Option 2/3

Receive PPF, Complete questionnaire Input part dimensions and

weight, Submit to Fab, Judge Fab PPF, Submit PPF result to Toyota

Container / Dunnage Fabricator

No Action

Receive PPF from supplier, complete PPF,

Submit PPF to supplier

Receive PPF, Complete PPF, Complete Questionnaire, Submit PPF

to Toyota

Supplier

Resp

Matrix

Responsibility

OPTION 5: Click on Part # to View PPF Progress. Talk to Fabricator off line if needed.

OPTION 4: See “Dual Design PPF Completion”

OPTION 1,2,3: (See “Pre PPF Completion”)



o Utilize the most efficient and smallest standard container in the sequence shown below: o Option 1: Tote without dunnage. o Option 2: Tote with dunnage. o Option 3: Knockdown bulk container without dunnage. (Target 45x48 footprint). o Option 4: Knockdown bulk container with dunnage. (Target 45x48 footprint). o Option 5: Rack/Bin without dunnage. (Target 45x48 footprint). o Option 6: Rack/Bin with dunnage. (Target 45x48 footprint).

General guidelines o Max weight per tote including dunnage & parts: 15kg. o Target less than 2 hours production per container. o Follow standard test procedures to confirm pack ensures part quality, refer to Section

3.0.H.12.a 3. Expectation of Quality:

a) Roles & Responsibilities, refer to Section 3.0.F:

b) Supplier is responsible to conduct lab testing and trials if required to ensure part and packaging quality throughout the system network.

c) If a packaging design is proposed by Fabricator or Toyota Party, Supplier MUST approve quality. If Supplier is concerned the proposed design cannot ensure part quality:

o Do not submit PPF in VPACS. o Contact NAMC Packaging Specialist immediately to share data concern and try to

resolve issue. o Utilize the “Issue Resolution” process if issue cannot be resolved.

d) Verification upon receipt (Supplier lead). o Upon packaging receipt from Fabricator, Supplier is responsible to confirm functionality,

workability, quality and specifications of each container to ensure quality and confirm tolerances are held.

o If there is an issue, Supplier must contact the Fabricator & NAMC immediately for next steps. NOTE: Supplier assumes responsibility of container quality after they are received.

4. Expectation when completing Pre PPF in VPACS: a) Supplier is responsible to confirm the below info is correct in VPACS:

Weight: Part, single container; Must be entered in Kilogram kg. Dimensions: Part, single container; Must be entered in Millimeter mm. Quantity Parts per Container (QPC): Single container and full pallet. Pictures: Correct picture of part, dunnage & container. Contact: Supplier contact information must be kept current.

Lead Support

4Packaging

Designc

Quality

OwnershipSupplier NAMC PKG

Supplier is responsible to provide RETURNABLE PACKAGING THAT

ENSURES PART QUALITY from Supplier production process, through Toyota

Logistics network and finally to NAMC part unload.

3.2.C.3

Item

Responsibility

Key Elements

SLIM

Section

Tier I responsible to design returnable packaging that ensures part quality throughout entire

network.

Supplier Production

Process

Toyota Logistics

Network

NAMC

Conveyance Part Removal



b) If specifications change throughout the development process, VPACS data MUST BE UPDATED to reflect the changes.

c) Dunnage which is NOT fixed should be entered in “dunnage 2” or “Other” section of Pre PPF.

*Dimensions MUST be in ‘mm’ & weight MUST be in ‘kg’. 5. Pre PPF completion process in VPACS – Refer to VPACS Supplier Training Manual Section 2B

and 2C.

6. PPF completion for stackable (vacuum form) trays a) Process applies to any parts packed in a stackable tray. b) Steps to complete PPF for a stackable tray:

Step 1: Request container code from NAMC Pkg Specialist

o Code will reflect packaging type, size, model & sequential number. o PKG CODE MUST BE CREATED BY TOYOTA PARTY. DO NOT CREATE

NEW CODE.

Step 2: Enter Packaging Fabricator 3 digit code. o If code does not exist, contact TEMA PUR.

Step 3: Add comment to describe full pallet set.

o Quantity trays per set, etc.

Step 4: Enter quantities o Container = Full pallet set. o QPC: Must reflect the quantity of parts per full pallet set. o Container / Layer: Must be equal to ONE. o Layer / Pallet: Must be equal to “1”.

Step 5: Confirm the container dimensions reflect the size of a full pallet set.



Example of completed stackable tray PPF

Note to Fabricators: The RCA will be issued based on number of full pallet sets, not per tray. Refer to the comment in Step 3 (above) to verify number of trays per set. If there is no comment available, please contact Supplier or NAMC Packaging Specialist to confirm quantities.

7. Carryover packaging design a) Use this process if current returnable packaging will be used for new model. b) Copy PPF to new PPF – Refer to VPACS Supplier Training Manual Section 13.

D. Trial Authorization and Ship

Toyota Party Responsibilities Approve/reject Pre PPF (Sec. 3.2.C) Decide authorzation method. Send trial authorization.

Supplier Responsibilities Understand authorization method. Receive trial authorization. Confirm trial shipment.

Fabricator Responsibilities Understand authorization method.

660

660

33012191143

1143 1219

660

152

1

NV454526-044L01

NL484505

NP484505

FAB

FAB

FAB

1 set = 4 trays + 1 pallet & 1 lid

STEP 1STEP 2

STEP 4

STEP 3

STEP 5

A

B

C

A

D

E

Trial Phase

M-11 ~ M-8

TOYOTA

(NAMC/TEMA)

TIER 1 SUPPLIER

PKG

FABRICATOR

ROLE

Ship Trial

Confirmation

Trial

Order

Auth

Trial

Result

Receive

Trial Auth

Receive

Trial Auth

Reject

Tier 1 Pkg

Fab PUR

Ship Trial

Confirmation

A

B



SUPPLIER FABRICATOR

OPTION 1 Auth To No Copy

OPTION 2 Auth To Auth Copy

OPTION 3 No Copy Auth To

OPTION 4 Auth Copy Auth To

Auth

Matrix

AUTH STYLE

SUPPLIER FABRICATOR

OPTION 1 Follow instructions at bottom of Auth form, Submit Ship and Readiness Dates Review Copy of Authorization, work with Supplier to Milestone Dates

OPTION 2 Follow instructions at bottom of Auth form, Submit Ship and Readiness Dates Auth Copy

OPTION 3 No Authorization Action Required Follow instructions at bottom of Auth form, Submit Ship and Readiness Dates

OPTION 4 Review Copy of Authorization, work with Fabricator to Milestone Dates Follow instructions at bottom of Auth form, Submit Ship and Readiness Dates

Auth

Matrix

AUTH RESPONSIBILITY

Receive trial authorization. Confirm trial shipment.

1. NAMC Packaging Specialist will determine if returnable packaging trial is necessary.

a) If no trial required, the Pre PPF will be approved as:

Approved with no trial required. Go to Section 3.2.F “Final PPF Completion”.

Approved as Final. Go to Section 3.2.G “Final Packaging Authorization”. b) If trial is required, go to next step.

2. Toyota Party will send authorization to Supplier or Fabricator. a) Understand authorization methods

Before sending trial authorization to Supplier and/or Fabricator for processing, Toyota Purchasing will determine authorization style from one of four options:

o VPACS authorization options:

o VPACS authorization responsibilities

b) Determining authorization methods

PLEASE NOTE: TMMC current process for Authorizations &/or Purchase Orders is outside of VPACS. Please refer to Section 3.0.I.2 “Packaging Purchase

Process”.



o Supplier will be responsible for Auth if Toyota Party uses Option 1 or 2. o Fabricator will be responsible for Auth if Toyota Party uses Option 3 or 4. o Supplier or Fabricator will have knowledge of Auth if Toyota Party uses Option 2 or 4, respectively. o You will be able to tell which Auth Option was used for each part by clicking on the ‘Do’ button and

opening the ‘Auth Download’ button. Example: Supplier options

3. Download Auth: Refer to VPACS Supplier Training Manual Section 3.A. Example of Authorization / RCA):

Option 1 Option 2 Option 4



4. Procure materials per the Returnable Container Authorization (RCA):

a) Procure order within 5 days of receiving authorization. b) Refer to Sec. 3.0.I.1.c for RCA details.

5. Fabricate prototype

Upon receipt, Suppliers and/or Fabricators are to utilize RCA as letter of intent to begin prototype design and fabrication.

Obtain quotes and provide them to the Purchasing group. (Refer to Section 3.0.I for “Packaging Purchasing Process”).

6. Supplier is responsible to have parts dedicated for prototype fabrication, testing and trials.

Part availability for specific packaging development activity is required.

Planning for part availability should be included in the vehicle development schedule.

NAMC packaging will not reimburse for parts. 7. Test prototype according to ASTM standards(refer to Section 3.0.H.12.a for “Testing Standards)

a) Supplier and Fabricator must attend tests to confirm results and understand detail of changes if they are required.

If testing fails, make changes and retest until it passes. b) If testing passes - review at Supplier. c) If Supplier rejects - make changes and retest. d) Repeat until it passes testing and Supplier review. e) If approved - ship trial to NAMC. f) High level process flow:

TOYOTARET CONTAINER AUTHPC - Logistics

Auth Date Part Number Comment1

Toyota Authorizing Part Description

NA Supplier Code Model #

Contact Name Ringi #

Contact Fax Container Code

Dunnage1 Code

Dunnage2 Code

w/ Copy To Pallet Code Comment2

NA Supplier Code Top Cap Code

Contact Name Stretch Code

Contact Fax Kanban Code

Other Code

Notes:

1. Procure order within 5 days of receiving authorization.

2. With this authorization, Toyota guarantees reimbursement of costs for the above quantities of packaging that are design compliant, reasonable, and verifiable.

a. Design compliant is defined as complying with Toyota documented specifications as recorded in the Supplier Packaging Policies & Standards Manual, the Packaging Proposal, any

other Toyota directives on file under documentation within VPACS and quantities as identified on this authorization. Production tooling is reimbursed on the first production packaging order.

b. Reasonable is defined as: i) being the most competitive rate between at least two sources unless mitigating circumstances prevail which are concurred to by Toyota in

advance; ii) competitive versus previously approved packaging; and/or iii) based on cost standards.

c. Verifiable is defined as supportable by fabricator quotations and/or invoices upon request or, as in the case of freight, by past performance history. Toyota reserves the right to

request copies of invoices as a spot audit check up to 1 year after the invoice date against a PO.

3. Supplier's invoice must be submitted with a copy of source's packing slip or the like proof of receipt of goods. It should be signed by supplier as having inspected product for

confirmation to packaging specifications, for reimbursement. Supplier’s invoice must reference Toyota’s PO number, which will be issued upon acceptance of Supplier’s quotation in WARP.

SAGM AGM SpecialistAMCOMGR

Auth#

Plant NAMC

NAMCYearMonthDay-0001

FABRICATOR

12345

AU

TH

TO

:

TIER I SUPPLIER

12345

2/12/2007 1234567890

123L

This authorization is limited to the NTE Limit listed underneath PUR Approval signatures above.

100

Qty. of

Dunnage

Authorized

Qty. of

Dunnage2

Authorized

Qty. of

Pallets

Authorized

Qty. of

Caps

Authorized

TM

MN

A

use

on

ly Qty. of

Containers

Authorized

Container

Size

Container

Type

24*15*11 Stackable Tote

Qty. of

Stretch

Authorized

200100 20 24

Qty. of

Label

Authorized

Parts per

Container

Containers

per Pallet

20

Qty. of

Kanban

Holders

4. Supplier agrees that this Returnable Container Authorization is an Operational Document as defined in the Toyota Engineering and Manufacturing North America, Inc. Terms and Conditions between TEMA and

Supplier (the "Terms and Conditions"), all of which are incorporated by reference as part of this Returnable Container Authorization. The Terms and Conditions are either contained in a separate document entitled

"Terms and Conditions" signed by both Supplier and TEMA or have been provided to Supplier previously in a separate communication from TEMA. Any additional terms and conditions proposed by Supplier will not

be part of the Terms and Conditions unless TEMA accepts them in writing signed by TEMA.

ST241511

AU

TH

CC

:

Qty. of

Other Pkg

Authorized

400 18

PC

PUR

PUR Approval$



8. Trial notification – refer to VPACS Supplier Training Manual Section 3B. a) Attach a “trial shipment” label to prototype prior to shipping.

Information required on trial shipment sheet: o Trial Description o Date trial shipped o NAMC packaging contact name o NAMC packaging contact phone number o Part number o Part description o NAMC o Model code o NAMC dock code o Move to location (within NAMC; provided by NAMC) o Supplier Name o Supplier Code o Shipper (origin):

Company name Contact name Phone number Email

o Logistics carrier name o Logistics carrier phone number

Paper used for the trial shipment sheet should be: YELLOW. o NAMC Packaging Specialist may request a different color.

Fa

brica

tor

Su

pp

lier

Fabricate

prototype

Test

prototypePass

Modify

prototype

Approve

Ship to

NAMC for

review

Ship to

Supplier for

review

No

Retest

prototype

Yes No

Yes

Pass

Yes

No



Example: ‘Trial Shipment Sheet’ (Also in Appendix & VPACS Documentation)

Supplier Name: SUPLA Supplier Code: 12345

Shipper (Origin) Company: Supplier or Fabricator Shipper (Origin) Contact:

Shipper (Origin) Phone #: Shipper (Origin) Email:

Logistics Carrier: Logistics Carrier Phone #:


NAMC Dock Code:

NAMC:

Enter Contact Name

Part Description:

1A

TMMMS

Unit Assy Conditioner

12345-67890

PACKAGING TRIAL SHIPMENT SHEET

DO NOT USE FOR PRODUCTION

Pkg trial area

123A

Move to location:

Model code:

DO NOT USE FOR PRODUCTION


Part Number:

Pkg Contact Phone

#:

NAMC Pkg Contact:

Trial Description: "HVAC Rack Pkg Trial"

Enter Contact #



9. Transportation set up and payment

Refer to “Packaging Transportation Process”. Section 3.0.H.14.a

TMMC shipments: TMMC will be advised and billed directly for all freight movement by the logistics carriers.

All other NAMC’s shipments: Add transportation cost to the prototype quote when submitting to TEMA PUR.

10. Suppliers and Fabricators need to ensure the prototype procurement, fabrication, testing,

approval and shipment, are complete by the milestone set by the NAMC Packaging Specialist.

E. Trial Review and Approval

1. Trial receipt at NAMC a) Toyota Party expectation is that Supplier has confirmed that the design will ensure part

quality throughout entire supply chain. b) Supplier and/or Fabricator may be requested to attend review at NAMC.

2. NAMC will review safety and workability with internal groups and send results of trial via VPACS.

a) If rejected:

Toyota Party will reject trial in VPACS with detail explanation of items requiring change and request a new trial.

If major concerns with NAMC feedback, Supplier / Fabricator may contact NAMC Packaging.

Supplier repeat “Trial Authorization and Ship”.

Repeat entire process until approved.

b) If approved with changes:

Toyota Party will approve trial in VPACS with detail explanation of items requiring change and request a new trial.

If major concerns with NAMC feedback, Supplier / Fabricator contact NAMC pkg.

Go to “Final PPF Completion”; Refer to Section 3.2.F.

c) If approved:

Toyota Party will approve trial in VPACS.

Go to “Final PPF Completion”; Refer to Section 3.2.F.

F. Final Packaging Proposal Form (PPF) Completion


Send result of trial.

Decide PPF design roles.



Send final PPF. Supplier Responsibilities

Understand design role; Refer to Section 3.2.C.1.a. Final PPF completion; Refer to Section 3.2.C.5.

Dual Design PPF completion; Refer to Section 3.2.C.5

1. The Final PPF completion and approval processes are common with the Pre PPF Completion and approval processes.

2. Please refer to Section 3.2.C for detail explanation of the following steps. 3. Toyota Party will send final PPF to Supplier or Fabricator to complete.

Understand design role: Section 3.2.C.1.a.

Determine design role: Section 3.2.C.1.b.

Final Packaging Proposal Phase

M-8 ~ M-6

TOYOTA

(NAMC/TEMA)

TIER 1 SUPPLIER

PKG

FABRICATOR

ROLE

Send Final

PPF

Decide Design

Method

Final PPF

Completion

Final PPF

Completion

View, Approve, or

Reject, PPF from

Pkg Fab

View, Approve, or

Reject, PPF from

Supplier

Final PPF

Review

Dual

Design

Tier 1 Pkg

Fab

Tier 1

Lead

Fab

Lead

Final PPF

Completion

Final PPF

Completion

Reject

C

B

A

A

B

B

C



Auth Phase

M-6 ~ M-4

TOYOTA

(NAMC/TEMA)

TIER 1 SUPPLIER

PKG

FABRICATOR

ROLE

Pkg

Auth

Receive

Auth

PUR

Tier 1 Pkg

Fab

Receive

Auth

4. Expectation of design: Section 3.2.C.2. 5. Expectation of quality: Section 3.2.C.3. 6. Expectation when completing Final PPF (Step 8) in VPACS: Section 3.2.C.4. 7. Final PPF completion process in VPACS: Section 3.2.C.5. 8. Dual design Final PPF completion process in VPACS: Section 3.2.C.5. 9. Final PPF approval (Step 9): Section 3.2.C.5.

G. Final Packaging Authorization


Approve/Reject Final PPF

Decide authorization method: o Fabricator o Supplier

Send Final PPF Supplier Responsibilities

Understand Authorization methods

Receive Final Authorization 1. The final authorization process shares some common steps with the trial authorization process. 2. Please see “Trial Authorization and Ship” for detail explanation of the following steps; Section

3.2.D. 3. Toyota Party will send Authorization to Supplier or Fabricator.

o Understand authorization methods: Section 3.2.D.2.a o Determine authorization methods: Section 3.2.D.2.b

4. Receive Authorization: Refer to VPACS Supplier Training Manual Section 5 5. Download authorization: Section 3.2.D.3 6. Procure materials per the RCA: Section 3.2.D.4 7. Returnable packaging quantity allocation

A

B

A

B

PLEASE NOTE: TMMC current process for Authorizations &/or Purchase Orders is outside of VPACS. Please refer to Section 3.0.I.2

“Packaging Purchase Process”.



a) Toyota Party will calculate returnable packaging quantity requirements for Toyota Party logistics network.

Calculation will include: o Supplier internal requirements (full / empty). o Transit time (include cross dock).

Transit lead time adjusted to reflect additional time required during winter months. o NAMC internal requirements (full / empty). o Pick up & delivery frequency.

This will account for additional pallets / lids and filler totes. o Buffer (transportation delays, border crossing, etc).

An RCA will be issued for amount required for Toyota Party logistics network. o Please refer to the RCA for quantity allocated for Supplier internal use.

b) Supplier responsible to procure additional returnable packaging if requirements are greater than amount purchased by Toyota Party.

Additional returnable packaging may be required to support the following: o Tier II or Direct supply loop o Off-site warehouse or any other off site facility loop o Work in Process (WIP) o Inventory buildup / batch production o Holiday / shut down differences

Keep all “proof of purchase” for Supplier purchases. These will be required for the “Shortage Investigation”; Refer to Section 3.0.L.

c) Quantity allocation visual (Also in Appendix & VPACS Documentation):



#


Procurement





Warehouse, etc.


requirements.




differences, etc


requirements.


Purchasing)


Supply Tier II.











allocation.


Toyota NAMC





Buffer:










NAMC Packaging

Supplier

1

4

3

2

5

6

.

.

.



H. Packaging Readiness


Review forecast packaging ready date

Review actual packaging readiness date Supplier Responsibilities Submit forecast readiness date Submit packaging readiness date

TOYOTA

(NAMC/TEMA)

TIER 1 SUPPLIER

PKG

FABRICATOR

Pkg Prep / Readiness Phase

ROLE M-4 ~ SOP

Review

Forecast

Review

Readiness

Submit Forecast

Ready Date

Submit Pkg

Readiness

Submit Pkg

Readiness

Submit Forecast

Ready Date

A

B

A

B



1. Fabricator schedule – Refer to VPACS Supplier Training Manual Section 7. a) Supplier and Fabricator work together to create a production schedule based on the

Supplier build requirement. b) Schedule must meet NAMC milestone for receiving returnable packaging.

2. Fabricator procures, fabricates and ships returnable packaging based on schedule developed

by Supplier and Fabricator; Refer to Section 3.2.H.1. a) Fabricator must contact Supplier prior to fabrication and/or shipping packaging to confirm

Supplier requirements. b) Fabricator to provide schedule update to Supplier (and Toyota Party if requested) on a

minimum of a weekly basis. c) If there is a delay in any step of the process, the Fabricator / Supplier must contact NAMC

Pkg specialist as soon as the issue is discovered.

3. Supplier receives returnable packaging from Fabricator a) Keep Bill of Lading (BOL) for invoicing purposes. b) Compare quantity on BOL to actual quantity received.

If quantity is incorrect, notify Fabricator immediately. If issue cannot be resolved, contact NAMC packaging specialist.

c) Confirm returnable packaging received has correct specifications, correct labels, is in good quality and functions properly.

If specifications, quality and functionality are not acceptable, notify the Fabricator and NAMC packaging specialist immediately.

Once packaging is received in, Supplier is responsible for quality and specifications.

4. Submit actual packaging readiness date in VPACS.

5. Supplier to ship in returnable packaging per NAMC instruction.

I. First Piece Verification

1. NAMC will verify packaging specifications are correct at first piece delivery.

2. If packaging specifications are incorrect per Final PPF, the NAMC Packaging Specialist will determine data error source. a) Supplier preparation error:

NAMC will notify Supplier.

Supplier will investigate root cause and provide countermeasure to NAMC.

NAMC approve: o Supplier begins shipping revised / correct packaging to NAMC immediately.

NAMC reject: o NAMC request changes. Refer to Section 3.3.H.3 o Supplier review requested changes and provide new countermeasure to NAMC.



o Continue process until approved.

b) VPACS data error:

NAMC will notify Supplier to update VPACS.

Refer to Section 3.3.G “Packaging Change Request VPACS Process”.

Please remember importance of VPACS data accuracy; Supplier responsible to confirm the below information is correct in VPACS: o Weight: Part, Single empty container; Must be entered in Kilogram kg. o Dimensions: Part, single container, full pallet; Must be entered in Millimeters mm. o Quantity Parts per Container (QPC): Single container and full pallet. o Pictures: Correct picture of part, dunnage & container. o Contact: Supplier contact information must be kept current.

J. Expendable (Back Up) Packaging Development

1. Expectation of design and quality for expendable packaging: a) Refer to Section 3.0.H.10 “Expendable Packaging Requirements”. b) Expendable packaging is referred to as ‘back-up’ within the VPACS system.

2. When entering expendable packaging specifications into VPACS, the Supplier is responsible

to confirm the below info is correct: a) Weight: Part, single container; Must be entered in Kilogram kg. b) Dimensions: Part, single container; Must be entered in Millimeters mm. c) Quantity Parts per Container (QPC): Single container and full pallet. d) Pictures: Correct picture of part, dunnage & container. e) Contact: Supplier contact information must be kept current.

3. Defining expendable packaging specifications in VPACS – Refer to VPACS Supplier Training

Manual Section 11A and 11B.



3. PACKAGING OPERATIONS

A. VPACS Part and Packaging Data Integrity

1. Supplier is responsible to confirm the below info is correct in VPACS not only in the packaging development process, but also ongoing through model life. a) Weight: Part, single container; Must be entered in Kilograms kg. b) Dimensions: Part, single container; Must be entered in Millimeters mm. c) Quantity Parts per Container (QPC): Single container and full pallet. d) Pictures: Correct picture of part, dunnage & container. e) Contact: Supplier packaging contact information must be kept current.

B. Packaging Shortage & Reimbursement: EXCEPT TMMC:

NOTE: This process is currently being made common between all NAMC’s. The change is dependent on a major upgrade to VPACS.

THIS SECTION REFERS TO ALL NAMC’s EXCEPT TMMC. 1. Supplier experiences returnable packaging shortage. 2. Follow the “Packaging Shortage & Reimbursement Process”:

(Also in Appendix & VPACS Documentation)

1 Day 2 Weeks 2 Days

Exte

rna

l

Lo

gis

tics

Op

era

tio

ns

NA

MC

Inte

rna

l

Lo

gis

tics

NA

MC

Pa

rts

Ord

erin

g

NA

MC

Pkg

Su

pp

lier

Returnable Packaging Shortage Investigation & Reimbursement Process: APPLIES TO ALL NAMC’s EXCEPT TMMC

Returnable

packaging

shortage

Submit

expendable

packaging

usage

notification in

V-PACS

Supplier

Issue

Approve

expendable

packaging

usage in

V-PACS

Reject. Provide detail

explanation and CM

required.

Ex: Too many internal

system days, damaged

returnable packaging out

for repair, Supplier build

ahead, etc

Yes

Review data

in V-PACS

& email

from

Supplier

Supplier expendable packaging usage tracking in V-PACS

(Data used for reimbursement if Toyota fault)

No

Begin

investigation;

Toyota Shortage

Investigation

Sheet

Qty

Authorization

Issue

Parts

Ordering

Issue

Internal

Conveyance

Issue

External

Logistics

Issue

Yes

Yes

No

No

No

Develop CM

to resolve

Issue

Yes

Yes

No

Operating Loss

Authorize

additional

returnable

packaging

Authorize

expendable

packaging use

in V-PACS

Toyota Issue

No

Yes

Check

“my page”

daily in

V-PACS

Supplier

notificationYes

No

Complete

Submit

packaging

shortage

investigation

sheet via email

Reject. Provide

detail explanation.

Receive expendable

&/or returnable

packaging

authorization in

V-PACS



3. Submit expendable packaging (back-up) usage notification in VPACS: Refer to VPACS Supplier

Training Manual Section 11C. a) Expendable packaging is referred to as ‘back-up’ within the VPACS system. b) Back-up ‘use’ button is ONLY available if:

Final returnable PPF submitted; Refer to Section 3.2.F.7.

Expendable packaging spec approved; Refer to Section 3.2.J.3. o If these are not completed, Toyota Party will NOT approve expendable packaging usage or

reimbursement.

4. Complete shortage investigation sheet (Also in Appendix & VPACS documentation). This sheet is

common for all NAMC’s including TMMC.

Supplier Returnable Packaging Shortage Investigation and NotificationI. Purpose

A. To help determine the root cause of returnable packaging flow issues.

II. Completion Instructions

A. Complete section III.C below. All information must be complete in order to investigate correctly.

B. Notify the affected NAMC of the shortage by submitting this form via email. (Please see "Toyota Pkg Contact List" in V-PACS Documentation section)

C. Submit email with the following information in the Subject line:

"Supplier Name, 5 Digit Supplier Code, PN you are referring, Returnable Packaging Shortage Notification and Rank"

*Rank:

III. Data Collection (complete blank fields.

A. Supplier Info B. Returnable Packaging Data

Submission Date V-PACS Returnable Packaging Code

Supplier Code V-PACS Dunnage Code

Supplier Name 10 Digit PN

Contact Name -Other PN's w/ Common Pkg:

Contact Ph #

Contact Email

C. Supplier Internal Investigation

1. Average number of returnable packaging shipped outbound daily to NAMC? (Qty returnable packaging/day)

2. How many total days of returnable packaging inventory is required in-house for your processes? (# of Days)

3. Has your facility purchased additional returnable packaging to support internal process requirements? Y/N

a. If Yes to purchase, how many extra returnable packaging has your facility procured? (Qty returnable packaging)

b. If Yes to purchase, please provide proof of purchase above qty authorized by Toyota.

4. Has your facility recently experienced a build fluctuation? Ex) Option Change, Volume Increase? Y/N

a. If Yes, how many returnable packaging per day increase from previous levels? (Qty returnable packaging/day)

5. Do the parts for these returnable packaging get produced daily? Y/N

6. Is there a production build ahead requirement for your facility in the near future? Y/N

a. If Yes, please explain.

7. Has this returnable packaging been recently re-sourced to your facility? Y/N

a. If Yes, who was previous supplier?

8. Has your plant recently been re-located?

a. If Yes, where was original location?

9. Does your facility use Toyota returnable packaging to ship to an off-site warehouse, sorting facility or any other location outside of the Toyota supply chain?

a. If Yes, how many returnable packaging are currently required for this loop? (Qty returnable packaging)

b. If Yes, how many returnable packaging were purchased by your facility for this loop? (Qty returnable packaging)

10. Are these returnable packaging being shipped outbound to another Toyota NAMC?

a. If Yes, specify the Toyota NAMC's.

b. Do you ship mixed NAMC totes?

11. Does your facility use Toyota returnable packaging to ship to a Tier II Supplier? Y/N



c. If Yes, are there current abnormalities in processes/inventories between your Facility & the Tier II? Y/N

12. Are all of your returnable packaging properly labeled? Y/N

13. Does your facility use the same returnable packaging as filler totes ? Y/N

a. If Yes, on average, how many of these returnable packaging are shipped as fillers daily? (Qty returnable pkg/day)

14. In the last 3 business days, is there confirmed receipt of exactly zero returns on your regular Toyota shipment? Y/N

a. If Yes, specify date and shipment # of the day Date / Shipment #:

Date / Shipment #:

Date / Shipment #:

15. In the last 3 business days, is there confirmed receipt of > 0 but < 50% returns on your regular Toyota shipment? Y/N


Date / Shipment #:

Date / Shipment #:

16. In-House abnormality returnable packaging inventory (complete counts of a to e) 0

a. Number of quarantined returnable packaging due to parts quality problem (Qty returnable packaging)

b. Number of quarantined returnable packaging due to build ahead for pending ECI (Qty returnable packaging)

c. Number of quarantined returnable packaging that are damaged (Qty returnable packaging)

d. Number of returnable packaging that are out for repair / maintenance (Qty returnable packaging)

e. Other number of returnable packaging, please specify.

17. Complete in-house inventory of returnable packaging (Include all from #16 in this count) 0

a. Total number of in-house returnable packaging full (Qty returnable packaging)

b. Total number of in-house returnable packaging empty (Qty returnable packaging)

18. Supplier comments

B. Collect data from suppliers when returnable packaging availability issues result in the use of alternate or expendable packaging. Use this data to

determine action plan to return to normal operating condition.

Issue Rank

Max Response

Time Example

Impact to Parts Shipment A 1 Day Rack shortage w/ no expendable (back-up) packaging available, etc.

No Impact to Parts Shipment B 5 DaysReturnable packaging shortage w/ expendable (back-up) packaging available, excess containers, reimbursement

follow up, etc.

)



a) Email shortage investigation sheet to NAMC Packaging Specialist.

Provide the following information in email subject line. Supplier name 5 Digit Supplier code PN you are referring Returnable packaging shortage notification Rank; explanation below

b) This information, in addition to NAMC internal investigation, will be used to find root cause of shortage.

c) NAMC will investigate: Parts overflow, returns overflow, yard build-up, quality issue, logistics route changes, production volume changes, etc.

5. Expendable packaging usage:

a) Only utilize expendable packaging if there are no other options.

Expendable packaging has a negative impact to safety, environment, cost, quality and productivity.

b) Toyota Party must pre-approve expendable packaging usage. 6. Toyota Party review expendable packaging usage. NOTE: Without expendable packaging usage approval, potential reimbursements cannot be processed.

7. Track expendable packaging usage – Refer to VPACS Supplier Training Manual Section 11E. 8. Notify end user of expendable packaging - Refer to VPACS Supplier Training Manual Section

11F. 9. Toyota Party review expendable packaging usage:

a) If usage / costs are deemed Supplier responsibility (Section 3.3.B.4 “Packaging Shortage Investigation Sheet”): Proceed to VPACS Supplier Training Manual Section 11C - Step 18.

Supplier responsibility includes shortage due to: Excessive damaged returnable packaging at the Supplier; Supplier using Toyota Party network returnable packaging for other purposes and no

additional quantity purchased by Supplier; i.e. Tier II, other OEM, warehouse shipments, etc; and

Internal processes at Supplier require more returnable packaging than allocated and no additional quantity purchased by Supplier; i.e. batch production build, quality quarantine, WIP, etc.

b) If usage / costs deemed Toyota Party responsibility (Section 3.3.B.4 “Packaging Shortage

Investigation Sheet”): Proceed to VPACS Supplier Training Manual Section 11 - Step 17.

Issue Rank

Max Response

Time Example


No Impact to Parts Shipment B 5 DaysReturnable packaging shortage w/ expendable packaging (back-up) available, excess containers,

reimbursement follow up, etc.



Toyota Party responsibility includes shortage due to: Quantity of returnable containers required is greater than quantity allocated; route lead time

(LT) increased, vehicle volume increase, excessive inventory of returnable packaging at Cross Dock or NAMC, etc.;

Excessive inventory of returnable packaging at Cross Dock or NAMC; Excessive damaged returnable packaging at NAMC or Cross Dock; Poor transportation flow; route changes, trailer blow outs, Cross Dock container flow, etc.;

and Internal process delay at NAMC; i.e. part &/or returns overflow, production downtime, etc.

Step 17: After expendable packaging end use notification and invoice submitted, data will be submitted to Toyota Party for approval and reimbursement processing.

NOTE: Reimbursement approval is not complete until status shows ‘Finish Approved’. Once status shows ‘Finish Approved’, payment will be processed via PeopleSoft with reference to the Auth number; Refer to Section 3.0.I.

C. Packaging Shortage & Reimbursement: TMMC

THIS SECTION REFERS ONLY TO TMMC. See Section 3.3.B for all other NAMC’s

1. Supplier experiences returnable packaging shortage. 2. Supplier follows TMMC Shortage Notification & Tracking Process. (Process Flow & Tracking Form

Available on VPACS in the Documentation Section). 3. Email the “Shortage Notification & Tracking Form” to the responsible TMMC packaging specialist

& also to [email protected].

a) Provide the following information in email subject line: Supplier name, 5-Digit Supplier code, Part number, Container shortage notification, Rank.

b) This information, in addition to NAMC internal investigation will be used to find root cause of shortage.

c) NAMC will investigate: Parts overflow, returns overflow, yard build-up, quality issue, logistics

route changes, production volume changes, etc. 4. TMMC determine if cause of shortage is:

a) Supplier process b) TMMC and/or Logistics Partner process c) Operational loss

Issue Rank

Max Response

Time Example


No Impact to Parts Shipment B 5 DaysReturnable packaging shortage w/ expendable packaging (back-up) available, excess containers,

reimbursement follow up, etc.




5. Reimbursement responsibility: a) Supplier responsibility:

Excessive damaged returnable packaging at Supplier. Supplier using Toyota Party network returnable packaging for other purposes and no

additional quantity purchased by Supplier; i.e. Tier II, other OEM, warehouse shipments, etc.

Internal process at Supplier requires more returnable packaging than allocated and no additional quantity purchased by Supplier; i.e. batch production build, quality quarantine, WIP, etc.

b) TMMC / LP responsibility:

Quantity of returnable packaging required is greater than quantity allocated; route lead time increase, vehicle volume increase, excessive inventory of returnable packaging at Cross Dock or NAMC, etc.

Excessive damaged returnable packaging at NAMC or Cross Dock. Poor transportation flow; route changes, trailer blow outs, cross dock container flow, etc. Internal process delay at NAMC; i.e. part overflow, returns overflow, production downtime,

etc.

c) Operational loss TMMC will authorize additional returnable packaging to fill system requirements.

6. Expendable reimbursement process (for expendable caused by TMMC process failure ONLY):

Refer to TMMC standard claims process, located on VPACS in the “documentation” section.

Process flow for suppliers and claim form are located on VPACS in the “documentation” section.

Submissions must be made by the 10th day of the month following the expendable use.

Submissions must be made to [email protected], cc the responsible PC Packaging Specialist.

Claims exceeding $5,000 require pre-authorization from TMMC.

Claim instructions are found on the sheets attached to the claim cover sheet (located on VPACS in the “documentation” section). Please review ALL claim instructions prior to submission to avoid the possibility of claim rejection.

D. Returnable Packaging Quantity Replenishment

1. Supplier initiated a) Reason for increased quantity requirements:

Ship point location change (FOB). b) Supplier responsibility:

Procure, receive and insert returnable packaging into the system by 1st shipment from new location.

c) Toyota Party responsibility:

n/a 2. Toyota Party initiated

a) Reason for increased quantity requirements:

Vehicle type change, volume increase or spec usage change.

Logistics route design change.

Ship point location change (FOB).




Authorizations

Shortage

TOYOTA

(NAMC/TEMA)

TIER 1 SUPPLIER

PKG

FABRICATOR

ROLE

Review

Forecast

Receive

Auth

Submit Pkg

Readiness

Submit Forecast

Ready Date

Review

ReadinessPkg

Auth

Receive

Auth

Submit Forecast

Ready Date

Submit Pkg

Readiness

PUR

Tier 1 Pkg

Fab

Track

History

b) Toyota Party responsibility:

Toyota Party (all NAMC’s except TMMC) responsible to authorize additional returnable packaging in VPACS.

TMMC will procure additional returnable packaging direct from Fabricator. Refer to Section 3.0.I.2.a.

c) Supplier responsibility: Procure returnable packaging authorized by the Toyota Party (for all NAMC’s except

TMMC). TMMC will procure additional returnable packaging direct from Fabricator. Refer to Section

3.0.I.2.a. Receive and insert returnable packaging into system at time of change implementation.

(For all NAMC’s). Enter forecast and actual readiness date in VPACS. Refer to Section 3.2.H.1

3. Operational loss

a) NAMC and Supplier shortage investigation activity must be completed to determine if shortage is due to operational loss / attrition.

b) Refer to Section 3.3.B.9.b. (All NAMC’s except TMMC) or 3.3.C.5.c. (TMMC). 4. Returnable packaging shortage authorizations PLEASE NOTE: The NAMC’s will require an investigation process prior to authorizing any additional packaging. Refer to Section 3.0.L.1 (All NAMC’s except for TMMC) or 3.0.L.2 (TMMC).

a) Toyota Party responsibilities

Decide authorization

Method o Fabricator o Supplier

Send authorization

Review forecast packaging ready date

Review actual packaging readiness date

b) Supplier responsibilities

Understand auth methods

Refer to Section 3.2.D

Receive authorization Refer to Section 3.2.G

Submit forecast readiness date Refer to Section 3.2.H

Submit readiness date

C

B

A

D C

A



Refer to Section 3.2.H

E. Container Re-label / Re-stencil Requirement

1. Supplier initiated a) Reason for increased quantity requirements:

Ship point location change (FOB) by Supplier. b) Supplier responsibility:

Procure, receive & apply new labels/stencils to all returnable packaging into the system by 1st shipment from new location.

2. Toyota Party initiated

a) Reason for increased quantity requirements:

Vehicle type or volume increase.

Logistics route design change.

Ship point location change (FOB) by Toyota Party.

b) Toyota Party responsibility:

Toyota Party (except TMMC) responsible to authorize additional labels in VPACS.

TMMC responsible to authorize Supplier to make additional label purchase.

c) Supplier responsibility: Procure, receive and insert into system at time of change implementation. Refer to Section 3.0.I.1.c (all NAMC’s except TMMC) and 3.0.I.2.a (TMMC) for

reimbursement processes. 3. Re-label / re-stencil process

a) Totes and stackable trays

Remove all the old labels from the returnable packaging.

Clean the surface of the old label location with a cleaning agent and let dry.

Apply the new labels at old label locations; confirm placement is correct.

Refer to Section 3.0.H.4.d (tote) and 3.0.H.8 (stackable tray) for label placement specs.

b) Knockdown bulk returnable containers Original ID plates are NOT removable on knockdown returnable containers. Similar sized ID plate must be placed over the top of the existing ID plates. Order ID plates with holes large enough to go over the rivets that were used to secure

original ID plate.

A

B

C

D

C

PLEASE NOTE: TMMC current process for Authorizations &/or Purchase Orders is outside of VPACS. Please refer to Section 3.0.I.2 “Packaging Purchase Process”.

B

D



Clean the surface of the old label location with a cleaning agent and let dry. Apply the new ID plate stickers over the top of the old ID Plates. Refer to Section 3.0.H.6.d for ID plate specifications.

c) Racks

Clean the area where the current stencil is located. Apply similar rack color paint over the old rack stencil. Create a stencil that meets all of the standard requirements explained in Section 3.0.H.7.c. Re-stencil your entire rack inventory.



Type Items Procedure Good No Good

Clean racks Check the cleanness of rack.

Structural

defects

Check for any structural frame being bent,

cracked or distorted.

Kanban

holders

Check for damage, missing holders,

missing plastic pouch.

Dunnage Check for damage, wear, missing dunnage.

Gates/LidsOpen gates/lids and check for smooth

movement. Ensure the hydraulic piston

securely holds the lid in open position.

Locking pinsCheck for binding. Must be fully engaged

into the frame.

Hydraulic

pistons

Check for proper mounting on each end,

proper bolting, excessive wear at pivot

points, no visible damage to piston rods.

Hold downCheck for missing hold down, wear on

strap.

VIS

UA

L IN

SP

EC

TIO

NF

UN

CT

ION

AL

INS

PE

CT

ION

F. Preventative Maintenance, Cleaning & Repair

1. Plastic container preventative maintenance and cleaning: a) Supplier manages activity. b) Supplier responsible for expense of labor and materials. c) Guidelines:

Ensure returnable container, dunnage and pallets are clean (no trash, debris, dirt, etc.), safe and in good working order prior to pick up from Supplier’s facility.

Returnable packaging is designed for indoor use only; Supplier assumes cost for repair, replacement or cleaning if returnable containers are kept outside.

Ensure the correct number of Kanban holders are attached to each container. 2. Steel container preventative maintenance and cleaning:

a) Steel returnable containers must be inspected prior to use. b) Daily inspection criteria:

Visual checks: o Clean racks o Structural damage o Kanban holders o Dunnage

Functional checks: o Gates / lids o Locking pins o Hydraulic pistons o Hold down locking bar

If racks are damaged, follow instructions in Section 3.3.F.3. Visual check sheet for daily inspection (Also in Appendix).



C) Bi-annual steel rack certification criteria: Visual checks:

o Clean racks o Structural damage o Welds o Dunnage o Kanban holders

Functional checks: o Gates / lids o Cables o Locking pins o Hydraulic pistons o Hinge o Hold down locking bar o Secondary lock

Instruction: o The designated months are May and November. o Utilize a paint pen and write the date of inspection on the inside of the left front pillar. o 100% certification completion is required in each designated month.

If racks are damaged, follow instructions in Section 3.3.F.3. Visual check sheet for bi-annual rack certification (Also in Appendix).



3. Returnable packaging repair a) Supplier Manages activity

NOTE: For TMMC Suppliers ONLY: Canadian Suppliers are to use the TMMC Repair and Maintenance Program. Maintenance costs through the TMMC Repair and Maintenance Program are billed directly to TMMC. For information on who your designated repair Fabricator is, contact your TMMC Packaging Specialist, by model.

b) Toyota Party reviews repair reimbursement request and compensates Supplier based on point of cause.

c) Guidelines:

Ensure returnable packaging is safe and in working order prior to pick up from Supplier’s facility.

Supplier and NAMC are both responsible to identify damaged returnable packaging.

Supplier can utilize Fabricator of choice to conduct repair. 4. Process for Supplier to pull out of system

a) Mark and /or receive the returnable container with the standard “damage tag” (See Appendix).


Clean racks Maintain the cleanness of rack.

Structural defectsCheck for any structural frame being bent,


Welds Check for wear, cracks, and distortion.

Dunnage Check for wear, missing dunnage.

Kanban holdersCheck for damage, missing holders,


Gates/Lids

Open lids/gates and check for the smooth


hold the lid in open position.

Cables

Check for frayed cable. Ensure the locking

pins and connections are secured to the

cable.


into the frame.

Hydraulic pistons




HingeCheck for tightness, presence of hinge

bolts.


strap.

Secondary lock Check for binding, any wear, bent.

VISU

AL IN

SPEC

TION

FUNC

TION

AL IN

SPEC

TION

BI-ANNUAL RACK CERTIFICATION

DAMAGED CONTAINER

DO NOT USE UNTIL REPAIRED.

NAMC

NAMC

Weld

Hinge

Lock

Shock

Gate

Handle

Foot

Door

KB Holder

Other

Damage Type

Damage Location



b) Pull out of system, mark the container and quarantine. c) The quantity of returnable packaging removed from the system awaiting repair and/or

replacement must not impact the supplier’s ability to ship the approved returnable packaging to Toyota. Actual quantity may require less than, but no greater than 0.5 day and should be reviewed with the NAMC.

5. Repair reimbursement process (ALL NAMC’s EXCEPT TMMC. Refer to Section 3.0.I.2.b for

TMMC claims process). a) Send email to NAMC Packaging Specialist for approval to repair and/or replace.

NAMC will review reimbursement request. Cause of damage will determine if compensation is approved or rejected. o NAMC cause of damage: NAMC provides reimbursement to Supplier for repair. o Supplier cause of damage: NAMC does not provide reimbursement to Supplier for

repair. If reimbursement approved:

o Authorization will be issued in VPACS to reimburse repair and/or replacement costs. Refer to Section 3.2.G.1.

o Supplier submits forecast and actual packaging readiness. Refer to Section 3.2.H.1.

o Supplier manages repair and replacement activity. If reimbursement rejected:

o NAMC Packaging Specialist will reply to email with explanation. o Supplier manages repair and covers costs associated. o Through the “Issue Resolution” process, the Supplier can escalate by providing

additional explanation. b) Container damaged beyond repair

If approved to replace, scrap container.

6. Process for Toyota Party to pull out of system a) Mark the container with the standard “damage tag” (See Appendix).



b) Place damage tag on right post facing the fork lift driver. c) Return to the Supplier. d) Supplier follow step 3.3.F.4.

7. Part quality issue due to lack of packaging maintenance, cleaning or repair:

a) Part will be rejected and charged to Supplier. b) Supplier is responsible for scrap, rework or repack costs.

DAMAGED CONTAINER


NAMC

NAMC

Weld

Hinge

Lock

Shock

Gate

Handle

Foot

Door

KB Holder

Other

Damage Type

Damage Location



G. Post SOP Returnable Packaging Change Request

Toyota Party Responsibilities:

Review PPF changes.

Approve/reject changes.

Create authorization (if needed). Supplier Responsibilities:

Update PPF after PPF final approved VPACS updated with new info

Wait for Toyota Party response Receive Auth; Refer to Section 3.2.G.1

Packaging Change

TOYOTA

(NAMC/TEMA)

TIER 1 SUPPLIER

PKG

FABRICATOR

ROLEDesign

POST-SOP ACTIVITIES

Request to make

change to PPF

Update PPF and

Save / Submit

Review Update

PPF from

Supplier

Approve?

YESNO

Reject

Need

Auth?

VPACS updated

with new info

VPACS updated

with new info

Create Auth

YES

NO

Receive Auth (see

Auth Phase details)

A

A C

D

B

C

D

PLEASE NOTE: TMMC current process for Authorizations &/or Purchase Orders is outside of VPACS. Please refer to Section 3.0.I.2.a “Packaging

Purchase Process”.

A C D

B A C

D

B A C

D



1. Supplier initiated a) Submit idea in VPACS. b) Must provide cost, quality &/or safety benefit analysis using the “Packaging Change Request

Form” via email. See Appendix for form. c) Toyota Party will approve or reject returnable packaging specification changes after evaluation. d) Toyota Party will provide detail if rejecting design request; Further negotiation between Toyota

Party & Supplier to reach consensus. 2. Toyota Party initiated

a) Toyota Party notification / request to Supplier. b) Provide cost, quality &/or safety benefit analysis. c) Supplier submit Post SOP design change request in VPACS as "approval" of design change. d) Supplier provide detail if rejecting design request; Further negotiation between Toyota Party &

Supplier to reach consensus. 3. Safety / ergonomic issue

a) At Supplier: Supplier responsible to propose, manage and pay for design change.

b) At NAMC: NAMC responsible to request and pay for change; Supplier responsible to manage activity

to change. 4. Quality issue

a) Supplier is responsible to provide RETURNABLE PACKAGING THAT ENSURES PART QUALITY from Supplier production process, through Toyota Party logistics network and finally to NAMC part removal.

b) Supplier responsible to propose, manage and pay for returnable package design changes if design is causing part quality issues.

5. VPACS process – Refer to VPACS Supplier Training Manual Section 12.



H. Delivery Problem Report (DPR)

1. Tool to communicate, track and permanently correct any Supplier non-compliance issues outlined in SLIM.

2. DPR issues

a) DPR can be written for any non-compliance issues within SLIM. b) Common examples below:

3. Process flow

a) Responsible NAMC Packaging Specialist to issue a DPR within one business day as non-compliance to packaging standards & procedures arises.

b) Supplier to send DPR back to NAMC within two business days. Detail countermeasure activity and timing are required.

c) Responsible Packaging Specialist to evaluate, file and communicate countermeasure to any affected party outside of the Packaging Section within one business day of receipt.

Packaging DPR Issue Categories

Pkg - Alternate/back-up container use without notification

Pkg - Alternate/back-up container causing part quality problems

Pkg - Alternate/back-up pallet use without notification

Pkg - Claims process missing documentation (TMMC only)

Pkg - Claims process non-compliance (TMMC only)

Pkg - Container label incorrect

Pkg - Internal inventory requirements greater than NAMC allocation

Pkg - Packaging development milestone timeline non-compliance

Pkg - Palletization Issue

Pkg - Repair/maintenance non-compliance

Pkg - V-PACS PPF specification inaccuracy leading to change requirement

Pkg - V-PACS PPF specification not same as shipped

Who 1 day 1 day 2 days 1 day

Group

Identifying

Packaging

Concern

NAMC Pkg

Supplier

Report

problem to

NAMC pkg

specialist

Identify non-

compliance

issue

Create

DPR

Send DPR

to Supplier

Complete

DPR with CM

detail

and timing

Review

CM

CM fix

issue

File

DPR

Email

copy of

DPR

No

Yes



4. DPR form

a) Step 1: NAMC will complete top half with detailed explanation of the non-compliance issue. b) Step 2: Supplier will complete bottom half with detailed explanation of the countermeasure and

implementation timing.

Please ensure ALL fields are completed.



NAMC DPR NUMBER

REPLY DATE

DUE ISSUE TO:

DATE:

TMMWV WV-1202101 PHONE: SUP. CODE

SUPPLIER:

NAMC PKG SECTION (This section is completed by NAMC PKG.)

SUPPLIER SECTION (Please complete all 5 boxes in this section.)

COUNTERMEASURE :

SUPPLIER EMAIL

DOCK CODE(S)

BA

Shortage notification tracking sheet indicates internal container requirement of 5 days. NAMC allocation is 2.25 days however there is no

indication that additional containers have been purchased to support 5 days inventory. It has also been indicated that same container is used to

ship to sub-supplier however no additional containers have been allocated for this loop.

PC Packaging

DELIVERY PROBLEM REPORT - DPR

DELIVERY PROBLEM CATEGORY

Pkg - Required Internal Inventory Greater than NAMC

Allocation

REPORTED BY:

DATE OF OCCURRENCE

Part Description (if applicable) Part Number (if applicable)

"N/A" if Not Applicable

SHIP DATE NAMC Order Number NEXT LEVEL SUPERVISOR CONTACT NAME

ROUTING: ORIGINATOR ------> NAMC PC -------> SUPPLIER -------> NAMC PC -------> ORIGINATOR

Or Correction Date

12/2/2010

SUPPLIER PHONESUPPLIER CONTACTNAMC PKG CONTACT

DETAILS OF ISSUE:

12345-67890

(Person Completing DPR.)Corrected at Supplier (CLEAN POINT) APPROVAL of ISSUING DEPT

Step 1

Step 2



I. Irreparably Damaged Packaging Notification Process (TMMC ONLY)

1. TMMC will provide disposition on packaging deemed to be irreparably damaged. NOTE: If there is any doubt whether the packaging can be repaired, the repair Fabricator will make the final assessment.

2. Supplier will follow “Irreparably Damaged Packaging Process”, flow and form located on VPACS

in the “Documentation” section.



J. Damaged Skid and Lid Process (TMMC ONLY)

1. TMMC will provide disposition on skids and lids deemed to be unsafe for shipment to TMMC. NOTE: If there is any doubt whether the skids and lids can be used, TMMC will make the final assessment.

2. Supplier will follow “Damaged Skid and Lid Process”, flow and form located on VPACS in the

“Documentation” section.



K. Packaging Disposition

1. Toyota Party will provide disposition on obsolete returnable packaging due to: a) Permanent volume fluctuation. b) Packaging revision c) Model build out:

NAMC Pkg will issue communication prior to build out. 2. Communication

a) If Supplier has obsolete returnable packaging, the “Excess Packaging Inventory Form” must be completed. Do not dispose of any returnable packaging without written approval from NAMC or TEMA Pkg.

b) There are two standard excess returnable packaging inventory forms: Standard returnable containers: totes, knockdowns, bins, pallet & top caps Nonstandard returnable containers: racks and stackable trays

c) The forms can be found in the Appendix and on the VPACS documentation. d) Supplier send completed form to NAMC Packaging Specialist.

3. Disposition options:

a) NAMC determine carryover potential:

If yes, Supplier to use for current / new model. b) NAMC determine retrofit potential:

If yes, packaging is modified to support new part or part design change. c) NAMC determine no future need:

If no need, NAMC sign excess returnable packaging inventory form and send to TEMA.

TEMA solicit other NAMC’s to find other uses.

If no application and the returnable packaging is standard, it may be sent to Toyota Party warehouse.

If there is no application and the returnable packaging is not standard, Toyota Party will provide recycling company information to Supplier.

4. The Supplier MUST wait for written instruction from NAMC or TEMA PKG before disposing

of any returnable packaging. 5. Procedure

a) Refer to “Packaging Operations: Roles and Responsibilities” Section 3.0.G.7 b) Process flow (See process flow in the Appendix and VPACS documentation):



RETURNABLE PACKAGING DISPOSITION

TEMA

Pkg

Supp

lierRe

cycle

Cente

r

Other

NAMC

’s

& TMS

Pkg

NAMC

Pkg

Fabri

cator

Decide

future use

of

returnable

packaging

from Build

out or

Supplier

Notification

Carryover

Retrofit

Rework

returnable

packaging

Cut off returns

at NAMC

Send to

Packaging

Fab

Send to

Tier I

Receive

Reallocated /

modified returnable

packaging

Make shipments

to NAMC

No change to

returnable

packaging

No future need

Utilize pkg for

other

application

Notify recycle

center (Toyota

will provide

contact)

Pick up

obsolete pkg

Notify NAMC

of excess

returnable

packaging

*Provide detail

list of Pkg

Specification

and Quantity

Solicit all NAMC’s

& TMS Pkg to

find if other

Requirements

exist

Requirement

existsYES

NO

Notify all

groups;

Original

NAMC, Tier I &

Requestor

Provide written

instruction to Tier I

Provide instruction

to Tier I

Requirement at

New Location

YES

Ship pkg to new

location

*Coordinated & paid

for by Requestor

NO

Re-label / re-

stencil & begin

use as

instructed by

requestor

Move asset

inventory in VPACS

*See VPACS Asset

Inventory Transfer



4. GENERAL INFORMATION

A. Toyota Party Contacts 1. VPACS Support

a) System issues, registration information: Toyota Helpdesk: (859.746.HELP) b) General VPACS questions: [email protected]

2. Toyota Party information

a) NAMC / TEMA packaging groups for plant / model specific questions. b) TEMA packaging purchasing group for WARP and other purchasing questions. c) Contact list is provided in VPACS; Refer to “Documentation” section.

B. Supplier / Fabricator Contact Information 1. Regularly check and update contact information in VPACS. 2. Notify NAMC specialist if there is a change in Supplier contact information.

C. Document Reference

1. Reference the “Documentation” section in VPACS for communication. 2. Below are some of the documents provided in the documentation section:

a) NAMC and TEMA Packaging Contact List

b) High Level Packaging Development Schedule

c) Packaging Development – Roles & Responsibilities

d) Packaging Operations – Roles & Responsibilities

e) Steel Rack Material Specifications

f) Steel Rack Drawings

g) Steel Rack Quality Check Sheet

h) Toyota Safety & Ergonomic Standards

i) TMMC Claims Submission Process

j) TMMC Packaging Claim Cover Sheet

k) Quantity Allocation Visualization

l) Shortage Investigation & Reimbursement

m) Supplier Issue Resolution Process

n) Trial Shipment Sheet

o) Shortage Process for all NAMC’s except TMMC

p) Shortage Process for TMMC

q) TMMC Expendable Tracking Sheet

r) Daily Rack Inspection Check Sheet

s) Bi-annual Rack Certification Check Sheet

t) Damage Repair Tag

u) Returnable Packaging Change Request Form

v) Delivery Problem Report (DPR) Process Flow

w) Delivery Problem Report Form

x) Packaging Disposition Process

y) Flow & Excess Inventory Sheets

3. Contact NAMC Packaging Specialist if a document cannot be found.

D. Process Reference

1. Misrouted packaging received at Supplier: Refer to SLIM Chapter 4 “Logistics Operations”. 2. Live parts returned to Supplier: Refer to SLIM Chapter 9 “Parts Ordering”.




5. APPENDIX A

A. Steel Rack Material Specifications; Section 3.0.H.7.d

1. Stacking cap

2. Kanban holder

Steel Kanban Holder Specification

Front View Side View



3. Folding post



11

GA

2

"x2

"



B. Steel Rack Drawings; Section 3.0.H.7.f

1. Standard base



2. Drawing template



Steel Rack Quality Check Sheet; Section 3.0.H.7.g

Quality Check Sheet

Part Number Date

Part Description Name of Inspector

Fabricator Job Description Name of Fabricator Co.

Sequential Number

Quality Check Sheet

Product Name Date; / / OK・・・レ

LINE ASSEM 48" X 66". DWG# 070211 Name; NG・・・NG

Description 1 2 3 4 5 6 7 8 9 10

Serial Number

A 66" +0 -1/8"

B 48" +0 -1/8"

C 51-3/8 +- 1/8"

D 21-13/16" +-1/8"

E 21-1/8 +-1/8"

F 18-5/8" +-1/8"

G 33-5/16" +1/16" -0

H 15-7/8" +1/16" -0

I 37-13/16" +1/16" -0

J 25-7/8" +1/16" -0

K STENCIL BASE: (FORMAT = "NAMC Code, 12345, ABCDE")

L SER # RT FT POST LFT REAR POST

M MAKE SURE SWIVEL CASTER AND PULL ARE ON SAME END

N REMOVE SHARP EDGES AND WELD SPLATTER

O Kanban Holders (2) -adjacent sides

P

Q 0

R 0

PASS (Inspector initial)

Remark

Include all

critical rack

and dunnage

placement

dimensions.

Comments:

Description

Rack #

60.5

48.5

60.5

48.5



C. Quantity Allocation Visualization; Section 3.0.K.1

#


Procurement





Warehouse, etc.


requirements.




differences, etc


requirements.


Purchasing)


Supply Tier II.











allocation.


Toyota NAMC





Buffer:










NAMC Packaging

Supplier

1

4

3

2

5

6

.

.

.



D. Trial Shipment Sheet (example); Section 3.2.D.8.a

Supplier Name: SUPLA Supplier Code: 12345

Shipper (Origin) Company: Supplier or Fabricator Shipper (Origin) Contact:

Shipper (Origin) Phone #: Shipper (Origin) Email:



DO NOT FOR USE PRODUCTION


Part Number:

Pkg Contact Phone #:

NAMC Pkg Contact:

Trial Description: "HVAC Rack Pkg Trial"

Enter Contact #


DO NOT FOR USE PRODUCTION

Pkg trial area

123A

Move to location:

Model code:

NAMC Dock Code:

NAMC:

Enter Contact Name

Part Description:

1A

TMMMS

Unit Assy Conditioner

12345-67890



E. Packaging Shortage & Reimbursement; Section 3.3.B.2

1. Process flow (all NAMC’s except TMMC)



2. Shortage investigation sheet (all NAMC’s)

Supplier Returnable Packaging Shortage Investigation and NotificationI. Purpose

A. To help determine the root cause of returnable packaging flow issues.

II. Completion Instructions

A. Complete section III.C below. All information must be complete in order to investigate correctly.

B. Notify the affected NAMC of the shortage by submitting this form via email. (Please see "Toyota Pkg Contact List" in V-PACS Documentation section)

C. Submit email with the following information in the Subject line:

"Supplier Name, 5 Digit Supplier Code, PN you are referring, Returnable Packaging Shortage Notification and Rank"

*Rank:

III. Data Collection (complete blank fields.

A. Supplier Info B. Returnable Packaging Data

Submission Date V-PACS Returnable Packaging Code

Supplier Code V-PACS Dunnage Code

Supplier Name 10 Digit PN

Contact Name -Other PN's w/ Common Pkg:

Contact Ph #

Contact Email

C. Supplier Internal Investigation

1. Average number of returnable packaging shipped outbound daily to NAMC? (Qty returnable packaging/day)

2. How many total days of returnable packaging inventory is required in-house for your processes? (# of Days)

3. Has your facility purchased additional returnable packaging to support internal process requirements? Y/N

a. If Yes to purchase, how many extra returnable packaging has your facility procured? (Qty returnable packaging)

b. If Yes to purchase, please provide proof of purchase above qty authorized by Toyota.

4. Has your facility recently experienced a build fluctuation? Ex) Option Change, Volume Increase? Y/N

a. If Yes, how many returnable packaging per day increase from previous levels? (Qty returnable packaging/day)

5. Do the parts for these returnable packaging get produced daily? Y/N

6. Is there a production build ahead requirement for your facility in the near future? Y/N

a. If Yes, please explain.

7. Has this returnable packaging been recently re-sourced to your facility? Y/N

a. If Yes, who was previous supplier?

8. Has your plant recently been re-located?

a. If Yes, where was original location?

9. Does your facility use Toyota returnable packaging to ship to an off-site warehouse, sorting facility or any other location outside of the Toyota supply chain?



10. Are these returnable packaging being shipped outbound to another Toyota NAMC?

a. If Yes, specify the Toyota NAMC's.

b. Do you ship mixed NAMC totes?

11. Does your facility use Toyota returnable packaging to ship to a Tier II Supplier? Y/N



c. If Yes, are there current abnormalities in processes/inventories between your Facility & the Tier II? Y/N

12. Are all of your returnable packaging properly labeled? Y/N

13. Does your facility use the same returnable packaging as filler totes ? Y/N

a. If Yes, on average, how many of these returnable packaging are shipped as fillers daily? (Qty returnable pkg/day)

14. In the last 3 business days, is there confirmed receipt of exactly zero returns on your regular Toyota shipment? Y/N


Date / Shipment #:

Date / Shipment #:

15. In the last 3 business days, is there confirmed receipt of > 0 but < 50% returns on your regular Toyota shipment? Y/N


Date / Shipment #:

Date / Shipment #:

16. In-House abnormality returnable packaging inventory (complete counts of a to e) 0

a. Number of quarantined returnable packaging due to parts quality problem (Qty returnable packaging)

b. Number of quarantined returnable packaging due to build ahead for pending ECI (Qty returnable packaging)

c. Number of quarantined returnable packaging that are damaged (Qty returnable packaging)

d. Number of returnable packaging that are out for repair / maintenance (Qty returnable packaging)

e. Other number of returnable packaging, please specify.

17. Complete in-house inventory of returnable packaging (Include all from #16 in this count) 0

a. Total number of in-house returnable packaging full (Qty returnable packaging)

b. Total number of in-house returnable packaging empty (Qty returnable packaging)

18. Supplier comments

B. Collect data from suppliers when returnable packaging availability issues result in the use of alternate or expendable packaging. Use this data to

determine action plan to return to normal operating condition.

Issue Rank

Max Response

Time Example

Impact to Parts Shipment A 1 Day Rack shortage w/ no expendable (back-up) packaging available, etc.

No Impact to Parts Shipment B 5 DaysReturnable packaging shortage w/ expendable (back-up) packaging available, excess containers, reimbursement

follow up, etc.

)



F. TMMC Packaging Shortage Process Flow; Section 3.3.C.2

Returnable Packaging Shortage Investigation & Reimbursement Process: APPLIES TO TMMC ONLY

TM

MC

Pa

cka

gin

gM

ate

ria

ls

Co

nve

ya

nce

Lo

gis

tics

Ma

teria

ls

Ord

erin

gS

up

plie

r

Packaging

Allocation

Confirmation

Supplier

Excess?Yes

Contact Supplier to

explain standards and

to resolve abnormality

Packaging

Underallocated?

No

Instruct Supplier to track


inventory and expendable

packaging tracking for

minimum of 2 weeks

YesLog investigation

results and close

Returnable

Packaging Order

& Procurement

No

Begin an Inventory/

Process Abnormality

Investigation

No

Submit Shortage

Investigation &

Notification Form

to PC Packaging

Log Shortage in

Production

Concern Tracking

Confirmed shortage of


inventory for greater than 2

weeks with no permanent

countermeasure

Alternate Packaging

Available for Supplier

Shipments?

Review with PC Management

investigation results and most

cost effective short term

countermeasure to maintain

production

No

Yes

Communicate to

Supplier timing of


inventory recovery to

relieve shortage

condition

No

Packaging

Claim?

Shortage

Resolved?EndYes

Returnable Packaging Inventory & Expendable Packaging Tracking

Packaging

Claim

Issue DPR for Corrective

Action &

Countermeasure

Complete and

return to TMMC Pkg

Yes

No

Inventory/Process

Abnormality Check

Inventory/Process

Abnormality Check

Inventory/Process

Abnormality Check

Provide Packaging

Specialist details

of countermeasure

and timing to get

back to standard

process/inventory

levels

Abnormality Found?

I.e. scrap reorder, actual order > actual

requirements and/or production, QPC

discrepancy, inventory overflow

Abnormality Found?

I.e. 1 for 1 return, container ID incorrect

Abnormality Found?

I.e. excess inventory at Cross Dock / Yard,

returns at wrong Cross Dock location

Yes

Yes

Yes

No

No

Start

2 weeks 2 days2 days



G. TMMC Expendable Packaging Tracking Sheet; Section 3.3.C.3

TMMC Supplier Tracking & Expendable/Alternate Usage Communication Prepared by: P.C. PPM - Packaging

D) Supplier Daily Tracking DetailTMMC Supplier Code

VPACS CONTAINER PACKAGE CODE

VPACS DUNNAGE1 PACKAGE CODE

ItemDock

CodeMon Tue Wed Thur Fri

Weekly

TotalMon Tue Wed Thur Fri

Weekly

Total

Cumm

Total

Lids Shipped 0 0 0

Lids Received From TMMC 0 0 0

Balance 0 0 0 0 0 0 0 0 0 0 0 0 0

Pallets Shipped 0 0 0

Pallets Received From TMMC 0 0 0

Balance 0 0 0 0 0 0 0 0 0 0 0 0 0

Returnable Container Shipped 0 0 0

Returnable Container Received From TMMC 0 0 0

Balance 0 0 0 0 0 0 0 0 0 0 0 0 0

Returnable Container Inventory (Empty)

Returnable Container Inventory (Full)

Returnable Container Inventory (In Process)

Total Container Inventory 0 0 0 0 0 0 0 0 0 0

Dock Code 1: Expendable/Alternative Container Shipped 0 0 0

Beginning Delivery Order Number (DON)

Ending Delivery Order Number (DON)







Total # of Expendable/Alternative Package Shipped 0 0 0 0 0 0 0 0 0 0 0 0 0

Dock Code 1: Cardboard Lid Shipped 0 0 0









Total # of Cardboard Lid Shipped 0 0 0 0 0 0 0 0 0 0 0 0 0

Dock Code 1: Wooden Skid Shipped 0 0 0









Total # of Wooden Skid Shipped 0 0 0 0 0 0 0 0 0 0 0 0 0

7. W

oo

d S

kid

Sh

ipp

ing

6. C

ard

bo

ard

Lid

Sh

ipp

ing

5. E

xp

en

da

ble

/

Alt

ern

ati

ve

Sh

ipp

ing

3.

Re

turn

ab

le

Sh

ipp

ing

ALL

4. I

n-H

ou

se

Co

un

t

Inventory

Count Time

Date: Fill Out Actual Date to According to the Day of the Week Below

1. L

id

Sh

ipp

ing

ALL

2. P

alle

t

Sh

ipp

ing

ALL

0

0



H. Daily Rack Inspection Check Sheet; Section 3.3.F.2.b


Clean racks Check the cleanness of rack.

Structural

defects

Check for any structural frame being bent,


Kanban

holders

Check for damage, missing holders,


Dunnage Check for damage, wear, missing dunnage.

Gates/LidsOpen gates/lids and check for smooth


securely holds the lid in open position.


into the frame.

Hydraulic

pistons





strap.

DAILY RACK INSPECTIONV

ISU

AL

IN

SP

EC

TIO

NF

UN

CT

ION

AL

IN

SP

EC

TIO

N



I. Bi-Annual Rack Certification Check Sheet; Section 3.3.F.2.c



I. CERTIFICTION INSTRUCTION 1. Certification is to be conducted bi-annually.

a. The designated months are May and November.

b. Utilize a paint pen and write the date of inspection on the inside of the left front pillar.

2. 100% certification completion is required in each designated month.

II. SCOPE OF INSPECTION CRITERIA


Clean racks Maintain the cleanness of rack.

Structural defectsCheck for any structural frame being bent,


Welds Check for wear, cracks, and distortion.

Dunnage Check for wear, missing dunnage.

Kanban holdersCheck for damage, missing holders,


Gates/Lids

Open lids/gates and check for the smooth


hold the lid in open position.

Cables

Check for frayed cable. Ensure the locking

pins and connections are secured to the

cable.


into the frame.

Hydraulic pistons




HingeCheck for tightness, presence of hinge

bolts.


strap.

Secondary lock Check for binding, any wear, bent.

VIS

UA

L IN

SP

EC

TIO

NFU

NC

TIO

NA

L IN

SP

EC

TIO

N



J. Damage Repair Tag; Section 3.3.F.4.a

TOYOTA

DAMAGED CONTAINER


NAMC

NAMC

Weld

Hinge

Lock

Shock

Gate

Handle

Foot

Door

KB Holder

Other

Damage Type

Damage Location



K. Packaging Change Request Form; Section 3.3.G.1.b

CHAPTER 3.5 APPENDIX

Company name: Part number:

Code: Description:

Short name: Model(s) affected:

Contact: NAMC(s) affected:

Contact phone: NAMC request sent to (one/sheet):

Contact email: Date of request:

Accept Accept

Reject Reject

Pkg Contact QC Contact

Date Date

Change Type: Current: Proposed: Comments:

QPC

Packaging type

Packaging size / dims

Dunnage style / design

Dunnage material

Implementation: Cost: Method to change: Comments:

QPC

Packaging type

Packaging size / dims

Dunnage style / design

Dunnage material

Benefit: Cost: Process: Comments:

Safety

Logistics

Packaging

Quality

Productivity

Overall Cost: Piece Price: Process:

$0

Accept

Reject

PC Pkg Contact

NAMC

Date

Supplier Information Part Information

Change Request Information

Overall impact:

Returnable Packaging Change Request Form

NAMC PC Packaging Evaluation

Response: Explanation / comments:

Details:Details:

Current condition (sketch or photo) Proposed condition (sketch or photo)

Supplier Evaluation (Supplier sign off must be complete prior to submitting to NAMC)

Pkg Response: QC Response:



L. Delivery Problem Report (DPR); Section 3.3.H.4

NAMC DPR NUMBER

REPLY DATE

DUE ISSUE TO:

DATE:

PHONE: SUP. CODE

SUPPLIER:

NAMC PKG SECTION (This section is completed by NAMC PKG.)

SUPPLIER SECTION (Please complete all 5 boxes in this section.)

COUNTERMEASURE :

(Person Completing DPR.)Corrected at Supplier (CLEAN POINT) APPROVAL of ISSUING DEPT

SUPPLIER PHONESUPPLIER CONTACTNAMC PKG CONTACT

"N/A" if Not Applicable

SHIP DATE NAMC Order Number NEXT LEVEL SUPERVISOR CONTACT NAME

ROUTING: ORIGINATOR ------> NAMC PC -------> SUPPLIER -------> NAMC PC -------> ORIGINATOR

Or Correction Date

DELIVERY PROBLEM REPORT - DPR

DELIVERY PROBLEM CATEGORY

REPORTED BY:

DATE OF OCCURRENCE

Part Description (if applicable) Part Number (if applicable)

SUPPLIER EMAIL

DOCK CODE(S)

DETAILS OF ISSUE:



M. Packaging Disposition; Section 3.3.K.2

1. Standard excess returnable container inventory sheet: Totes, knockdowns, bins, pallets & top caps.

EXCESS PACKAGING INVENTORY: TOTES, KD's, BINS, PALLET & TOP CAPS

Packaging Detail: Please fill out the appropriate sections.

Totes, Ropaks, Bins, skids, lids… etc. (example in yellow) Toyota use ONLY (blue)

Model Type Dimensions Quantity Make Folding? Dunnage? Color Instruction

Corolla Tote 12x7x8 296 Orbis No Yes Gray sample

Corolla Skid 48x45 56 Schafer N/A N/A Blue sample

Corolla Topcap 48x45 20 Schafer N/A N/A Black sample

NAMC agrees to release the above packaging to be reused or recycled at the disgression of the TEMA Packaging Reuse Coordinatior

By signing this, the supplier agrees to follow the Toyota direction shown above in blue for all of the packaging shown.

Street Address:

City:

Contact Number:

State:

Contact Name:

NA Code:

Supplier Name:

PRINTED NAME PRINTED NAME

PHONE # PHONE #

SIGNATURE SIGNATURE

DATE DATE

SUPPLIER PC WINDOW SUPPLIER PC MANAGER

PRINTED NAME

PHONE #

DATE

NAMC PC WINDOW



2. Unique excess returnable container inventory sheet: racks & stackable trays.

EXCESS PACKAGING INVENTORY: RACKS & STACKABLE TRAYS

Street Address:

City:

State:

Contact Name:

Contact Number:

Racks & Vac Formed Trays ONLY (example in yellow) Toyota use ONLY (blue)

Model Type Dimensions Quantity Part # Commodity Color Instruction

Corolla Rack 12x7x9 1,386 00000-00000 Exhaust Manifold Blue sample

Corolla Vac Tray 48x42x6 78 00000-00000 Drive Shaft Blue sample

NAMC agrees to release the above packaging to be reused or recycled at the disgression of the TEMA Packaging Reuse Coordinatior

By signing this, the supplier agrees to follow the Toyota direction shown above in blue for all of the packaging shown.

NA Code:

Supplier Name:

PRINTED NAME PRINTED NAME

PHONE # PHONE #

SIGNATURE SIGNATURE

DATE DATE

SUPPLIER PC WINDOW SUPPLIER PC MANAGER

PRINTED NAME

PHONE #

DATE

NAMC PC WINDOW



3. Process Flow:

RETURNABLE PACKAGING DISPOSITION

TE

MA

Pkg

Su

pp

lie

rR

ecycle

Ce

nte

r

Oth

er N

AM

C’s

& T

MS

Pkg

NA

MC

Pkg

Fa

bric

ato

r

Decide

future use

of

returnable

packaging

from Build

out or

Supplier

Notification

Carryover

Retrofit

Rework

returnable

packaging

Cut off returns

at NAMC

Send to

Packaging

Fab

Send to

Tier I

Receive

Reallocated /

modified returnable

packaging

Make shipments

to NAMC

No change to

returnable

packaging

No future need

Utilize pkg for

other

application

Notify recycle

center (Toyota

will provide

contact)

Pick up

obsolete pkg

Notify NAMC

of excess

returnable

packaging

*Provide detail

list of Pkg

Specification

and Quantity

Solicit all NAMC’s

& TMS Pkg to

find if other

Requirements

exist

Requirement

existsYES

NO

Notify all

groups;

Original

NAMC, Tier I &

Requestor

Provide written

instruction to Tier I

Provide instruction

to Tier I

Requirement at

New Location

YES

Ship pkg to new

location

*Coordinated & paid

for by Requestor

NO

Re-label / re-

stencil & begin

use as

instructed by

requestor

Move asset

inventory in VPACS

*See VPACS Asset

Inventory Transfer



N. TMMC Challenger ASN; Section 3.3.H.14.b

Load at Location ATTENTION: Denise Moreau x2259

[email protected]

Ph: 1-800-268-2096

fax: 519-651-0101519-653-1089

ZIP:

PHONE & FAX:

COMMENTS: This document is to be faxed or emailed 2 days prior to Pickup.

NMFC (Class):

EARLIEST P/U DATE:

(pieces and dimensions)

C las s

# o f fe e t

to ta l w t in lb s

Pieces:_____#______ TMMC ref #

Size of rack or skid: dim s o f s kid o r rac k

STREET ADDRESS:

CITY/STATE:

Zip / Po s ta l C o deC ity, Sta te

888 - 888 - 8888Re c ie v e r's nam eaa am - x x p m

COMPANY NAME:

CITY, STATE:

Zip

PHONE:

Zip / Po s ta l C o de

FAX:

ADDRESS:

Ship To Location

CONTACT NAME:

SHIPPING HOURS:

888 - 888 - 8888888 - 888 - 8899Ship p e r's Nam ex x am to x x p m

Space required on

truck (linear feet or

pallet positions)

TOTAL WEIGHT (LBS)

COMPANY NAME:

TMMC/CHALLENGER ADVANCE SHIPPING NOTICE**151L Program**

Shipper's Numbers

ORDER NO.:

Fab ric a to r Nam eStre e t and Unit #C ity, Sta te

Tie r 1 s up p lie rStre e t and Unit #

Shipping Information

CONTACT NAME

QUANTITY

(US Shipments only)DELIVERY HOURS:

DESCRIPTION

(TMMC part#)

PICKUP NO.:

Fab ricato r Re f #

CMF BOL #

Fab ricato r Re f #BILL OF LADING #.:

Date frt re ady to s hip

L___xW___xH____

(inches)



O. TMMC Challenger Bill of Lading; Section 3.3.H.14.b



A. High Level Schedule with Milestones; Section 3.0.E

No

rth

Am

eric

an P

acka

gin

g D

evel

op

men

t H

igh

Lev

el S

ched

ule

N-3

6N

-35

N-3

4N

-33

N-3

2N

-31

N-3

0N

-29

N-2

8N

-27

N-2

6N

-25

N-2

4N

-23

N-2

2N

-21

N-2

0N

-19

N-1

8N

-17

N-1

6N

-15

N-1

4N

-13

N-1

2N

-11

N-1

0N

-9N

-8N

-7N

-6N

-5N

-4N

-3N

-2N

-1S

OP

N+1

N+2

N+3

PR

OJE

CT

VE

HIC

LE

MIL

ES

TO

NE

S

Ref

eren

ce

N-6

Beg

in 5

day

s af

ter

rece

ivin

g A

uth;

Ref

er to

Sec

. 3.0

.I fo

r P

urch

asin

g pr

oces

s.

SU

PP

LIE

R

N-1

0

NA

MC

NA

MC

Fin

al P

PF

app

rova

l pro

cess

NA

MC

SU

PP

LIE

RS

up

plie

r sh

ip t

o N

AM

C

NA

MC

Rec

eive

, rev

iew

& a

pp

rove

/rej

ect

If re

ject

; Sup

plie

r / F

abric

ator

cre

ate

chan

ges

& r

epea

t V-P

AC

S s

teps

5-7

N-1

3N

-10

Ste

p 6

N-1

3N

-6S

tep

7

Su

pp

lier

sub

mit

Fin

al-P

PF

in V

-PA

CS

NA

MC

rev

iew

/ ap

pro

ve

Sup

plie

r / F

ab b

egin

pro

cure

men

t

Pac

kag

ing

au

tho

riza

tio

n

Pac

kagi

ng r

eadi

ness

NA

MC

NA

MC

Act

ual

rea

din

ess

Fo

reca

st r

ead

ines

s

Pre

viou

s m

odel

Pkg

dis

posi

tion

1st p

iece

shi

p ve

rific

atio

n

Bud

get t

rack

ing

Ste

p 3

Sup

plie

r su

bmit

stan

dard

& c

ost e

ffici

ent d

esig

n if

no B

M d

esig

n pr

ovid

ed.

NA

MC

N-1

6N

-10

Ste

p 4

NA

MC

may

app

rove

, rej

ect a

nd/o

r re

ques

t cha

nges

to p

ropo

sal.

Co

mm

ents

V-P

AC

S S

tep

N-1

8

N-1

6N

-13

NA

MC

Up

load

new

par

t lis

t in

to V

-PA

CS

NA

MC

Sen

d P

re-P

PF

to

Su

pp

lier

N-1

7N

-15

N-1

6N

-10

N-1

8N

-18

N-1

8N

-18

N-1

6N

-10

N-1

3N

-6

N-1

0N

-6

N-1

0N

-6

N-1

0N

-8

N-1

0N

-6

N-1

0N

-3

N-6

N+3

N-1

0N

-3

N-1

0N

-6

N-3

N+2

N-1

5N

+3

AC

con

firm

atio

n

Pre

-PP

F a

ppro

val p

roce

ss

Pro

toty

pe

auth

ori

zati

on

Tria

l app

rova

l pro

cess

Su

pp

lier

sub

mit

Pre

-PP

F in

V-P

AC

S

NA

MC

rev

iew

/ ap

pro

ve

Mile

sto

ne

Nam

e

Adv

ance

d pl

anni

ng d

igita

l ass

embl

y ac

tivity

New

mod

el b

udge

t cre

atio

n

Adv

ance

d C

once

pt (

AC

) de

velo

pmen

t

Res

po

nsi

bili

ty

TE

MA

/ N

AM

C

NA

MC

TE

MA

/ N

AM

C

SU

PP

LIE

R

TE

MA

/ N

AM

C

SU

PP

LIE

R

NA

MC

SU

PP

LIE

R

SU

PP

LIE

R

SU

PP

LIE

R

NA

MC

NA

MC

Fin

ish

Sta

rt

N-3

6N

-18

N-3

2N

-16

N-2

7

SU

PP

LIE

R

Dev

elop

& g

ain

cons

ensu

s on

Ben

chm

ark

(BM

) de

sign

for

high

cos

t par

ts.

Sup

plie

r co

nfirm

if A

C B

M d

esig

n is

ok.

Ste

p 1

Will

upl

oad

as s

oon

as a

vaila

ble;

ofte

n de

laye

d

Ste

p 2

Will

sen

d B

M p

ropo

sal i

f dev

elop

ed in

AC

dev

elop

men

t

Ste

p 5

Sup

plie

r / F

abric

ator

cre

ate

prot

otyp

e, te

st a

nd r

evie

w a

t Sup

plie

r fa

cilit

y.

Ste

p 10

Ste

p 8

Sup

plie

r to

con

firm

ALL

dat

a in

PP

F is

cor

rect

.

Ste

p 9

NA

MC

may

rej

ect a

nd/o

r re

ques

t cha

nges

to p

ropo

sal.

NA

MC

/ T

EM

A w

ill p

rovi

de d

ispo

sitio

n on

obs

olet

e pk

g; R

efer

to S

ec. 3

.3.J

.

Ste

p 12

Ent

er A

CT

UA

L da

te p

acka

ging

is r

ecei

ved

at S

uppl

ier

faci

lity.

Ste

p 11

Ent

er F

OR

EC

AS

T r

eadi

ness

dat

e ba

sed

on fa

bric

ator

sch

edul

e.

NA

MC

con

firm

pac

kagi

ng s

pecs

at f

irst s

hipm

ent r

ecei

pt

Pre

vio

us

Mo

del

Pac

kag

ing

Dis

po

siti

on

VS

PA

SK

4S

EG

enzu

CF

1W

1A

2W

2A S

OP

Ad

van

ced

Pla

nn

ing

(A

P)

Dig

ital

Ass

emb

ly A

ctiv

ity

Ad

van

ced

Co

nce

pt

(AC

) D

evel

op

men

tA

C

Co

nfi

rmat

ion

Pre

PP

F A

pp

rova

l

New

Mo

del

Bu

dg

et C

reat

ion

/ P

kg Q

ty C

alcu

lati

on

Pro

to A

uth

ori

zati

on Tri

al A

pp

rova

l Pro

cess

Fin

al P

PF

Ap

pro

val

Pkg

Au

tho

riza

tio

n

Bu

dg

et T

rack

ing

Pac

kag

ing

Rea

din

ess

1st

Pc

Sh

ip V

erif

icat

ion

QC

S /

LO

Par

t L

ist

rele

ase

& u

plo

ad /

Sen

d P

re P

PF

to

Su

pp

lier

D E

A

B

CF

G H

I

J K

L

M

O

N

D EA B C F G H I J K L M ON

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