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Visteon Packaging Guidelines. Generals Requirements and Intercontinental Shipments

Released: 16/2/2015

Overview

These guidelines replace and supersede any and all previous editions. These guidelines have been prepared to assist purchased part suppliers in meeting the Visteon Packaging requirements as well as normal transportation and handling to help insure part quality for shipments to all Visteon manufacturing locations globally. Visteon facilities may have specific regional and local requirements that should be considered in additional to these guidelines. In cases where the local Visteon facility has supplemental guidelines, the most severe, most strict guideline will apply. If there is a viable and documented business reason for a deviation from these guidelines, the purchased part supplier must receive approval for the deviation in writing from the respective Visteon facility. Purchased part suppliers are obligated to insure that they are informed about the latest requirements and that all shipments to Visteon are compliant. Due to the significant importance to Visteon’s operations, compliance to these packaging requirements is mandatory and will be continuously monitored. Non-compliance to the instructions contained in this manual will be brought to the supplier’s attention and if required through the Visteon Supplier Report Card progress. Any incremental costs generated by non-compliant packaging may be billed back to the suppliers shipping location. Any persistent violations or recurring problem will be referred to the appropriate Visteon buyer for corrective action as necessary. Questions regarding these guidelines should be directed to Visteon Packaging Engineering: [email protected] or Visteon Plant Packaging Engineering, receiving

location. An electronic copy of this guideline and other packaging guidelines according the shipping region are available for suppliers to download in Visteon Supplier Portal, www.epgpics1121.com, PICS menu. Uncontrolled when printed.

mailto:[email protected]

http://www.epgpics1121.com/

Visteon Packaging Guidelines - Generals Requirements and Intercontinental shipments 2/25

Contents I. General Requirements

I.1. Part quality I.2. Packaging Materials I.3. Manual Handling I.4. Government Regulations I.5. Packaging Quantities I.6. Load stability I.7. Hazardous Materials I.8. Environmental Considerations I.9. Transportation Considerations I.10. Cube considerations I.11. Laws and Regulations

II. Packaging Design III. Returnable Packaging

III.1. Standards Containers III.2. Unique container owned by supplier III.3. Returnable Back-up / Emergency Expendable Packaging III.4. Maintenance and Cleaning

IV. Standard Expendable Packaging IV.1. Standards Carton sizes IV.2. Standards Intercontinental Carton sizes IV.3. Internal Dunnage IV.4. Carton Performance IV.5. Styles of Corrugates Boxes and Carton Closure IV.6. Standard Expendable Wood Pallet

IV.6.1. Acceptable Pallet Styles IV.6.2. Wood Packaging Material

V. Pallet Loading V.1. Acceptable Examples V.2. Unacceptable Examples

VI. Shipment Labeling and Identification VI.1. Transportation Labels VI.2. Unit Load Master Label VI.3. Internal Packaging Label VI.4. Containers Label Field Position

VII. Supplier Requirements VII.1. Supplier Responsibility VII.2. Packaging Approval VII.3. Packaging Testing VII.4. Supplier Checklist VII.5. Alternative Solutions

VIII. Packaging Approval Process IX. Visteon Packaging Information Collection System – PICS Appendix A: Packaging Selection Flowchart Appendix B: Supplier Checklist Appendix C: Carton Pallet Loading – Standards Intercontinental Carton Sizes Appendix D: Quick reference Guide


I. General Requirements Regardless of packaging material, style of packaging, the ship from or ship to locations, these general requirements will be in effect. Purchased part suppliers should review and insure all packaging are in line with these expectations. The packaging requirements contained in this brochure have been developed to assist Visteon’s Suppliers select packaging which satisfies production part quality, economic objectives and the Visteon receiving plant’s needs.

I.1. Part Quality The purchased part supplier is responsible to insure their packaging delivers their part to the final point of use, in a production ready and damage-free condition, assuming normal handling, transportation, storage, and in-plant movements.

Visteon will provide packaging approval based off the container selection, container size, container density, and overall design to help insure in plant requirements are met. The purchased part supplier is responsible for the design and development of the packaging to fit all variants and design levels of the sourced part and to insure the part quality is maintained to the final point of use.

The supplier is responsible for providing adequate protection of their parts. Some packaging systems and components may require additional protection such as corrosion, surface abrasions, or static build-up.

For some type of products, the plastic materials used on the package solution will need to be ESD, due the components specification or assembly location Plant. The use of preservatives or other special packaging must be reviewed and concurred by the receiving Visteon facility prior to adoption.

I.2. Packaging Materials

Whenever possible, easily recyclable and/or reusable material should be used: such as paper corrugated, plastic containers, thermoformed plastics, etc. Certain non-recyclable materials can be more difficult and costly to recycle or dispose of, such as foamed plastics, and therefore should only be used when no suitable substitute is available.

Plastic material must be labeled with the appropriate material code in accordance with “The Society of the Plastic Industry” guideline and/or in accordance with local/or national government regulations.

Supplier must also insure that materials are easily separated for recyclability. For example, foam pieces glued to a paper corrugated sheet can be difficult to separate and properly recycle. Metal banding must not be use.

I.3. Manual Handling The gross weight of containers designed for hand carrying and handling shall not exceed 12 kilograms or 26.4555 lbs.(weight of the product plus weight of the packaging materials), even if palletized. Gross weight of containers is the weight of the product plus the weight of the packaging materials.


Containers/boxes should be modularized to fit standard units load shipping sizes. Deviation will require authorization from the receiving Visteon facility, and should be addressed as early as feasible in the packaging development process. Standard Ergonomics Guidelines must be considered during the packaging development process. Purchased part suppliers should confirm their proposal meets all local, country and regional ergonomic requirements.

I.4. Government Regulations It is the purchase part supplier’s responsibility to insure that all packaging conforms to all government and transportation rules and regulations for the ship from location and the ship to location.

I.5. Packaging Quantities

Packaging part quantity and/or lot quantity need to meet the average daily parts volume: annual volume per working days. Packaging part counts (pieces per container/boxes) shall not vary and containers/boxes should always be shipped with full quantities except when authorized by the receiving Visteon facility and should be marked accordingly (i.e. “Final Release” or “Balance Out”). One container/box shall hold only one part number. Mixed loads are only acceptable with prior approval from the receiving Visteon facility prior to shipping.

I.6. Load Stability All packs must have sufficient vertical strength and stability to withstand tiered heights to maximize in transit freight. Proper unitization is critical to insure maximum load stability. Stretch/shrink wrap is a preferred method of unitization. Banding, seatbelts or other stabilizing techniques must adequately secure palletized loads. Metal strapping, nailing, stapling or gluing is not an acceptable method for securing the loads.

Shipping Unit Load Maximum Height is: 1100mm or 43 inches.

Shipping Unit Loads must be able to be stacked up to 2200 millimeters or 86 inches high in storage and in transit.

No pyramid loads are ever acceptable as they reduce the load stackability, will not allow Visteon to maximize freight, and risk product damage. Containers must be oriented so that they will fully utilize the length and width of the pallet. To help insure vertical integrity containers must not overhang the edge of the pallet.

I.7. Hazardous Materials Transport regulations will vary for hazardous materials depending on the transportation mode. Hazardous materials shipped to any Visteon facility must comply with all applicable international and local regulations and be accompanied by the necessary shipping documentation and safety data sheets.


It is the purchased part supplier’s responsibility to pack any hazardous good in appropriate approved packaging and to label and mark all unit loads containing hazardous materials according to regulations.

I.8. Environmental Considerations Expendable container systems should be designed and engineered for use within reasonable and foreseeable environmental conditions. The receiving Visteon facility can provide specific restrictions on time frames and expected order rates. In order to be kept clean some parts may require additional protection during transportation, storage, and/or plant environment. Expendable container systems should be designed to withstand a wide variation in temperatures from -35°C to +65°C (-30°F to +150°F) and high humidity (up to 90%) during handling, transit and storage. Material can also be in storage for up to 6 months in some cases.

I.9. Transportation Considerations Every effort shall be made to minimize the cost of transportation. This process involves routing instructions and conveyance selection, as well as packaging design. Packaging must be designed for transport logistics that are common for overseas supply chains. Suppliers should consider all possible modes of transit including truck, rail, ocean and potentially air freight.

Failures to comply with these specifications that result in excess transportation costs may result in charges to the supplier. In most instances, Visteon Corporation will designate the most economical mode of transportation, and will specify carrier and carrier's routes. If the purchase order does not designate the mode of transportation, consult the Central Transportation Team.

I.10. Cube Considerations For all shipments, Visteon Transportation has the goal to utilize a minimum of 90% of the available shipping space inside the conveyance.

If the proposed packaging cannot meet this target, the proposal needed to be accorded with the Central Transportation Team and Packaging Engineer from the shipping location.

I.11. Laws and Regulations Compliance with all federal, state, country and local laws and regulations must be maintained.


II. Packaging Design An introduction to Lean Manufacturing Visteon’s objective is to be a World-Class Lean Manufacturer. A key enabler of the lean manufacturing process is the packaging for production part shipments from the supply base. Through the use of optimum sized containers, material flow through the system and line-side ergonomics is improved. The overall effect for packaging is a shift from large packs containing many hours stock, to Small Lot Packaging, containing an agreed target level of stock. When combined with the Synchronous Material Flow Program, Small Lot Packaging has the following benefits within Visteon plants.

Eliminates waste at all stages of the production cycle.

Manual delivery replaces mechanical delivery to line-side. Fork-lift movements can be replaced by dedicated replenishments cycles.

Reduction in physical space requirements. Line-side stock location and market-place storage areas can be reduced.

Improves direct labor efficiency. The containers can be ergonomically presented to the Operator to maximize their efficiency.

Increases inventory turn-over rates.

Reduces non-value added inventory.

Smoothes production flow.

Reduces batch sizes. Modular Small Lot Packaging can be ordered in smaller unit whilst maintaining level load units, average daily parts volume.

These benefits are not exclusive to the receiving plant. With the necessary focus of material flow processes, the Supplier can also realize all these efficiencies. Overall, there will be a minimal, to zero, on-cost for operating Small Lot Packaging. Standard packaging specifications should be documented and available at all times. Packaging must not vary between shipments. Depending on the manufacturing facilities location the packaging design can change. Supplier need to consult also the Packaging Guidelines according to facility location and contact receiving plant Packaging Engineer. Two types of packaging termed in general are: Returnable: recycle/re-usable/ durable packaging materials Expendable: as name indicate, packaging material used for one-time use The Container Selection Flow Chart should be used to help select the proper container/carton box size. See Appendix A: Packaging Selection Flowchart.


III. Returnable Packaging Returnable packaging material need to be used, wherein the vendor is located near plant and wherein cost economics favors the usage, in accordance with the Logistics Agreement, agreed between Visteon buyer, Visteon MP&L and Plant Packaging Engineer. Due to environmental, cost, and quality considerations, Visteon encourages the use of returnable packaging where feasible and lower total cost solution. Returnable packing include standard plastic containers, KLT (Klein Ladungs Traeger, German for small plastic modular container), plastic bins, PP boxes, unique containers owned by supplier, FSC / FLC (Folding Small Container / Folding Large container), specialized pallets, trolleys, etc… Depending on the manufacturing facility location the packaging design can change. Supplier need to consult also the Packaging Guidelines according to the facility location and Plant Packaging Engineer.

III.1. Standards Containers Most parts are compatible with standard size containers, which are readily available from several manufacturers. The choice of container should be mutually agreed between the Supplier and the receiving Visteon plant. Contact the Plant Packaging Engineer in order to provide assistance and direction on this decision. It is far better that this is agreed early in the sourcing process to ensure that the chosen container type is feasible and that the total cost calculation is as close as possible to the final solution. The following guidelines should also be adhered to:

The containers must be identified and color coded according Durable Packaging Plant Identification. You must agree the color with the receiving plants as they may already have reserved specific colors for other components. Each container should have the words 'Return to [Company] – [Location]' clearly stenciled on at least two sides of the container.

Supplier must verify container, ID and labeling Requirements with the receiving Visteon facility prior having the packaging material manufactured.

The containers must be robust enough to withstand an industrial environment. It is

the Supplier’s responsibility to maintain, clean and repair damaged or dirty containers and dunnage.

If the pack is not a self-contained unit, then containers must be easily assembled

into palletized unit loads.

Ensure that sufficient containers are available given the intended logistics process. Use the System Days on PICS, float, and shipping frequency to determine this. The final number of containers must be agreed by the Plant Packaging Engineer.

Agree piece price implications with Purchasing. Ensure that the cost for container

control and return freight have been included in Supplier's costs unless other


arrangements have been negotiated with Purchase and the receiving Visteon plant.

Arrange a test shipment into the plant and ensure that you obtain formal buy-off of the rack from the receiving plant before purchasing production volume of the container. Talk initially with the Plant Packaging Contact of the receiving Visteon plant.

The purchased parts supplier needs to maintain/track the quantity of returnable containers used in the supply-chain, in accordance with the Logistics Agreement, agreed specific for the part/component/supply.

Remember responsibility to ensure part quality and continued safe ergonomic use of Supplier owned durable containers remains the responsibility of the Supplier at all times.

Please consult Packaging Guidelines according the Shipping region for more details and contact Plant Packaging Engineer.

III.2. Unique Container owned by supplier Some parts may require unique or specialized packaging designs due to part characteristics, automated handling, ergonomics, etc. Special characteristics include part geometry, fragility, cleanliness, etc. Visteon Plant Packaging Engineering can provide, upon request, a list of recommended sources for the design and manufacture of unique packaging.

III.3. Returnable Back-Up / Emergency Expendable Packaging Expendable packaging is only to be used for emergency shipments when approved durable containers are not available due to unforeseen circumstances (internal packaging can be expendable for standard containers). It is essential that an emergency expendable packaging solution is developed and a few shipments worth are always available at the Supplier location. Returnable Back-Up / Emergency Expendable Packaging is absolutely mandatory since the ordering system, internal/external logistics systems, and manufacturing processes are dependent on consistent container size and part quantity.

Emergency expendable containers must mirror the size and part quantity of the returnable container it replaces. It is EXPECTED that suppliers maintain a sufficient

quantity of emergency packaging in inventory at all times.

III.4. Maintenance and Cleaning The part supplier is required to conduct routine container inspections and perform required repairs to insure container/dunnage are in a safe and useable condition and capable of delivering a quality product. This typically involves replacement of container dunnage, details and assemblies, replacement and/or tightening of fasteners, removal of debris and dirt, etc. at no additional cost to Visteon. It is expected that containers will be repaired in a timely manner to avoid supply interruptions.


IV. Standard Expendable Packaging

IV.1. Standards Carton Sizes

Expendable packaging need to be use, wherein the vendor is situated at a considerable distance from the Visteon Plant location, or for all purchased parts sourced from an imported location (different countries). Some receiving locations have special requirements, which may limit the maximum size, weight or closure method used. Suppliers with any questions must contact the Receiving Visteon facility for details. Any undesired cost generated by the usage of non-standard packaging (for example: part damage, insufficient freight utilization, re-packing, etc.) will be charged back to the Supplier even though the Visteon plant packaging engineer has approved the related #1121 Forms.

IV.2. Standards Intercontinental Carton sizes

The sizes listed below are the most common standards Visteon carton sizes to be used for Intercontinental shipments. Other sizes can be used must properly and efficiently cube out the export pallet footprint. The full unit load height, including pallet and all cartons, can not exceed 1100mm (43”). Please see Packaging Guidelines from the Shipping region for more details.

IMC Carton

Number

Exterior Dimensions CARTON SPECIFICATIONS

(mm) (in) Burst

Strength BCT

L W H L W H (kPa / PSI) Kg

IMC010 140 240 120 9.5 5.5 4.75 1320 (275) 208

IMC020 140 240 240 9.5 5.5 9.5 1320 (275) 208

IMC030 280 240 120 11 9.5 4.75 1320 (275) 243

IMC040 280 240 240 11 9.5 9.5 1320 (275) 243

IMC050 280 480 120 19 11 4.75 1320 (275) 294

IMC060 280 480 240 19 11 9.5 1320 (275) 294

IMC070 560 240 120 22 9.5 4.75 1320 (275) 301

IMC080 560 240 240 22 9.5 9.5 1320 (275) 301

IMC081 560 375 240 22 14.75 9.5 1320 (275) 630

IMC090 560 480 120 22 19 4.75 2180 (275) 692

IMC100 560 480 240 22 19 9.5 2180 (400) 692

IMC110 560 480 480 22 19 19 2180 (400) 692

IMC120 560 960 120 38 22 4.75 2470 (275) 737

IMC130 560 960 240 38 22 9.5 2800 (500) 1179

IMC140 560 960 480 38 22 19 2500 (500) 1074

IMC150 1120 480 120 44 19 4.75 2470 (275) 952

IMC160 1120 480 240 44 19 9.5 2500 (500) 1102

IMC170 1120 480 480 44 19 19 2500 (500) 1102

IMC180 1120 960 240 44 38 9.5 3524 (500) 1950

IMC190 1120 960 480 44 38 19 3524 (500) 1950

IMC193 1120 960 560 44 38 22 3524 (1100) 1950

IMC197 1120 960 600 44 38 23.6 3524 (450) 1950

IMC197HC 1120 960 730 44 38 29.2 3524 (450) 1950

IMC200 1120 960 960 44 38 38 3524 (450) 1950


Note: The Specification listed in this guideline is minimum recommendations. Suppliers are responsible for part quality and may need to adjust factors as required. Outside dimensions must remain consistent to insure full utilization of the export pallet and sea containers. Appendix C: Carton pallet loading according Standards Intercontinental Carton Sizes.

IV.3. Internal Dunnage

According most plants requirements, carton boxes are not accepted inside the manufacturing area, the parts are repack into internal containers, in those cases parts are received into plastic bags with internal label. The usage of a plastic bag allows a quick repack for a plastic box, and avoids cardboard part contamination. For some type of products, the plastic materials used on the package solution needed to be ESD.

IV.4. Carton Performance

Pallets needed to be stackable up to 2200 millimeters in transit or in storage. Stacking strength shall be a value that adequately protects the contents of the carton through a complete transport cycle. Carton stacking strength shall be verified through a Box Compression Test (BCT), available on Visteon request. Hand holes in cartons reduce BCT values and may require stronger material.

The wall thickness/strength of the carton will be dependent on the product it will be carrying and should be selected by the Supplier as appropriate. Carton toughness shall be specified with a minimum value that adequately protects the contents of the carton through a complete transport cycle. This minimum value assures performance when the carton is shipped either non-palletized or in a pallet-loads of mixed cartons. Other factors that need to be taken into consideration that can degrade carton performance include: Leaking sea containers Long storages


IV.5. Styles of Corrugated Boxes and Carton Closure

Regular Slotted Container (RSC): FEFCO Code - 0201 Top and bottom are of equal length; folded flaps meet only if box is square.

Half Slotted Container w/Cover (HSC): FEFCO Code – 0200 (HSC), 0312 (Cover) Can be used as combination shipper and shelf package and for various applications where cover must be removed and replaced.

Bulk / Pallet Box Style Consists of a half slotted container with a lid. Should be used for larger components. Can be made with a perforated drop-down door to aid in the loading and unloading of the components.

Pallet Box Style Containers: FEFCO Code - 0310 Consists of a top and bottom tray with a tube style body. Should be used for larger components. Can be made with a perforated drop-down door to aid in the loading and unloading of the components.

Strippable reinforced tape or spot gluing are the only acceptable methods for carton closure. If gluing is selected, glue transfer to the part surface is unacceptable. Half Slotted Containers with full layer lids should be used whenever possible to eliminate the requirements for carton closures.


IV.6. Standard Expendable Wood Pallet Expendable packaging needed to be loaded on an expendable pallet. The recommended pallet shipments are:

1200 x 1000 mm

48 x 40 inch

1140 x 990 mm or 45 x 39 inch

IV.6.1. Acceptable Pallet Styles

Block Style Pallet with full perimeter bottom

Block Style Pallet without full perimeter bottom

Runner (Stringer) Style Pallet.

In some facilities the one-way pallet can be used.

IV.6.2. Wood Packaging Material Pallets of other than wood construction are to be reviewed and concurred on by Visteon Packaging Engineering and the receiving activity prior to use. ALL SUPPLIERS SHIPPING MUST CONFORM TO ISMP 15 REQUIREMENTS FOR WOODEN PACKAGING MATERIALS. It is the supplier’s responsibility to insure their material is compliant with the most up to date requirements

ISMP 15 The ISPM guideline covers all forms of solid wood packaging material (SWPM) that may serve as a pathway for pests posing a risk mainly to living trees. Included under this guideline are wood packaging material such as crates, boxes, packaging cases, dunnage, pallets, cable drums and spools/reels, which can be present in almost any imported consignment, including consignments that would not normally be subject to phytosanitary inspection. For further information please visit International Phytosanitary Portal (IPPC) at: https://www.ippc.int Not covered under this guideline is processed wood material that is processed in such a way that is free from pests (e.g. plywood). There are also other materials that can be considered that do not require treatment such as corrugated pallets and plastic pallets.


All treated material must be marked with an official stamp identifying that the wood is debarked, the type of treatment used, the country where application was done and the registration number of the body which applied it. Symbol – must resemble closely to the example shown below. Country Code – The country code must be the International Organization for Standards (ISO) two-letter country code (shown in the below example as “XX”). Producer / Treatment Provider – A unique code assigned by the NPPO to the producer of the wood packaging material or treatment provided who applies the mark (shown in the below example as “000”) Treatment Code – Treatment code is an IPPC abbreviation for the approved measure used (shown in the below example as “YY”). HT – Heat Treatment MB – Methyl Bromide

V. Pallet Loading To minimize manual handling, all containers must be palletized unless part volumes and shipping releases to individual receiving plants are insufficient to complete one full palletized layer. Contact your Visteon plant release analyst to ensure standard release quantities and facility Packaging Engineer. Cartons are to be palletized in full layers only (no "pyramiding"), to allow tiered unit loads in transit and storage. Suppliers must size all cartons to fully utilize the length and width of the pallet. Shipping Unit Load Maximum Height is: 1100mm or 43 inches Shipping Unit Loads must be able to be stacked: 2200 millimeters or 86 inches high in storage and in transit.

V.1. Acceptable Examples


Proper Stacking on pallet

Proper Unitization

Proper material strength,

Proper utilization of space (cube utilization)

Proper Banding

V.2. Unacceptable Examples


Improper Unitization – cartons have shifted

Improper strength material, overhang

Cartons are not sized to pallet properly, overhang

Cartons are overhanging the pallet

Improper markings – cartons/pallet loads must be able to stack up to 2,200mm or86”

Pyramid loading, improper pallet


Pyramid loading

Pyramid loading, improper height

Improper Banding

Wood Crates

VI. Shipment Labeling and Identification Incoming material is to be identified by the supplier with an identification label (Hand written information is not acceptable). The label is designed to improve the productivity and controls at suppliers and Visteon Corporation, by allowing effective and efficient capture of data. This data will be used for production counts, warehouse input/output, shipper generation, forwarding, freight transfer control, receiving, and other inventory controls, etc. These specifications for the Shipping/Parts Identification Label will benefit both Supplier and Visteon. Labeling requirements and specific Identification requirements shall be determined by the MP&L Visteon facility according the receiving specifications. It is the supplier’s responsibility to insure they have the most recent labelling requirements and to confirm the labeling requirements with the receiving Visteon facility.

VI.1. Transportation Labels

All individual containers/boxes must be identified with two labels placed on adjacent corners and parallel to the top edge of the pack. If the part is packed in durable containers, the label holders must be used.

VI.2. Unit Load Master Label

Any unit load of one individual part number must have a Master Label summarizing the contents.


VI.3. Internal Packaging Label

For components delivered on reels or internal bags require an additional bar coded internal packaging label. This must be present to maintain the components identity after it has been removed from the outer transportation packaging. Please consult Packaging Guidelines from the Shipping region for more details.

VI.4. Container Label Field Positions Below are the label locations for the various shipping packs:

Box or Carton Identical labels shall be

located on two adjacent sides (wrap

around label acceptable). The upper

edges of the labels should be as high as

possible from bottom of carton.

Cartons on Pallet Each carton shall be individually labeled as described above. Each pallet shall contain a master label or mixed load label.

Drums, Barrels, or Cylindrical Containers. Identical labels shall be located on the top and near the center of the side

Pallet Box

Identical labels shall be located on two

adjacent sides (wrap around label is

acceptable).

Telescopic or Set-Up Containers

Identical labels shall be located on two adjacent sides of the outer box. Some applications may also require identification of the inner box (wrap around label is acceptable).


Bag

Place one label at the center of face.

Roll This example is no longer appropriate. If used, must be in a container

labeled on 2 adjacent sides.

Plastic Modular Container, Tote Identical

labels shall be located on two adjacent

sides in designated locations

Plastic Pallet Box


adjacent sides in designated locations

Collapsible Sleeve Pack


adjacent sides in designated locations.

VII. Supplier Requirements

VII.1. Supplier Responsibility

Each supplier is responsible for the design of their product packaging and for ongoing adherence to the Visteon Packaging Guidelines to insure that their product is transported and received at the Visteon manufacturing location in quality approved condition.

VII.2. Packaging Approval

The supplier is responsible to insure that all packaging has been approved prior to any production shipments being made.

VII.3. Packaging Testing Suppliers are responsible for any testing required to insure their product packaging will perform as required. If possible, testing should be done prior to any shipments being made to insure the robustness of the proposed packaging design. Suppliers can contact Visteon Packaging Engineering or shipping location Packaging Plant Engineer for assistance to determine the proper testing protocol to help insure the proposed packaging will be sufficient. Visteon Packaging Engineering maintains the right to approve the test protocol in certain cases as needed.


VII.4. Supplier Checklist To insure that you used the Visteon Packaging Guidelines properly the supplier Checklist located in Appendix B at the end of this guideline should be utilized to confirm all critical items have been completed. It is recommended this page be printed and used for each unique part being shipped.

VII.5. Alternative Solutions

If a lower total cost solution exists that is not compliant with these guidelines the supplier should contact Visteon and provide an analysis for review. In some cases returnable, durable, and pooled containers may provide a benefit for intercontinental shipments and can be reviewed on a case by case basis.


VIII. Packaging Approval Process When the supplier has received confirmation of the sourcing from Visteon Purchase, the supplier should refer to the following steps to gain packaging approval. Visteon has developed a web based packaging data form which can be filled out and submitted electronically. It is mandatory that all purchased part suppliers utilize this system. For further instructions and using this system please visit http://www.epgpics1121.com Please Note: where the sourced component is part of a major new program the supplier may be working with a Visteon Supply Chain Project Team Engineer. If this is the case the supplier must involve this Supply Chain contact in all steps of the Packaging Approval Process.

Step 1-Review RFQ (Request For Quotation) Check specification and costs originally submitted on RFQ

Step 2-Complete and submit #1121 forms via PICS: If there are any variances form the original tender then make the alterations provided and agree revisions with Visteon Purchasing. The information stated by the final version and the approved #1121 form cannot be contradictory. Submit 1121s required packaging related info at http://www.epgpics1121.com site or under Supplier Portal. Please Note: No hard copies of the 1121s form will be accepted.

Step 3- Obtain receipt of approval: Once authorized the Visteon Plant contact will inform the supplier via written message sent out through the PICS system on the approval of submitted packaging specification. It is the Supplier’s responsibility to insure that they have an approved 1121form in PICS prior to shipment of parts into a Visteon plant. To obtain this approval the Visteon plant may request a trial shipment prior to delivery of first production parts. This could be in addition to any shipments made during the Production Part Approval Process. Contact the Plant or the Supply chain contact to determine if a trial is required.

Please Note: An approved #1121 form is mandatory part of the PSW approval process. Any pack received which does not according to the approved 1121s may be repacked at the discretion of the Plant and the associated cost charged back to the supplier.

Step 4- Ship parts to receiving Visteon plant: Retain a copy of the approved 1121s form and proceed with shipments.

Please Note: Supplier is responsible for the design and development of the production pack to fit all variant and design levels of the sourced part and insure the part quality is maintained through the complete supply chain to the final point on use.




IX. Visteon Packaging Information Collection System - PICS

Visteon has developed a website packaging data form where the packaging data can be filled out and submitted electronically. It is mandatory that all purchased part suppliers use this system for all new parts and engineering level changes of current parts. Packaging Information Collection System Supplier User’s Guidelines (PICS) for guidance available on www.epgpics1121.com Visteon will provide packaging approval based off the container selection, container size, container density, and overall design to help insure in plant requirements are met. The purchased part supplier is responsible for the design and development of the production packaging to fit all variants and design levels of the sourced part and to insure the part quality is maintained to the final point of use. Screen shot from Visteon PICS:



Appendix A: Packaging Selection Flowchart

Determine the overall size of the component.

Select the smallest recommended standard carton box/container into which the component fits.

Select the smallest recommended standard pallet

box/bulk into which the component fits.

Fill the carton box/container with as many parts as

possible.

Fill the pallet box/bulk with as many parts as possible.

Does the carton

box/container weight more than 12kg when full?

Does the pallet box/container exceed the

manufacturer's weight capacity

when full?

Submit your 1121 via PICS for Approval.

Contact Packaging Engineering

receiving Plant

Contact Packaging Engineering

receiving Plant

NO

YES

NO

NO

YES

YES

NO

YES

Will the components fit into a standard

carton box/container?

Will the components fit into a standard pallet box/bulk?


Appendix B: Supplier Checklist

To help insure that you have used these Packaging Guidelines properly please use the below checklist to review and confirm all critical items have been completed. It is recommended this page be printed and used for each unique part being shipped.

Do you have the most recent Visteon Packaging Guidelines and have you read and understood what is required?

Have you confirmed your selected packaging conforms to the contents of the Visteon Packaging Guidelines?

Were ergonomic requirements reviewed as part of the packaging design process and the gross weight in not excessed 12 kg?

Has every effort been made to use only packaging material which can be recycled?

Has the appropriate protection methods been reviewed and implemented if necessary for corrosion, abrasion, static build up, etc.?

Does your pallet size comply with the requirement 1200 x 1000 mm maximum?

Does the Shipping Unit Load maximum height is 1100 mm?

Has testing been performed to help insure your Shipping Unit Load is robust enough to support stacked loads up to 2200 millimeters or 86 inches in storage and during transit?

Does your packaging meet all government and transportation rules and regulations?

Will all palletized loads be properly secured and no steel banding will be used when shipping to Visteon?

Did you insure there will be no overhang on your shipping pallets and there will be no pyramid loads shipping to Visteon? These are not acceptable under any circumstances.

Do you have an appropriate packaging supplier selected that can provide the correct materials in the correct quantities at the required times?

Have you completed and submitted the Visteon 1121 form via the PICS website (www.epgpics1121.com) for approval?

Have you received full packaging approval via the PICS website (the watermark stating “APPROVAL PENDING” will be removed once full approval has been received)?

Have all internal processes been documented to insure that all shipments are meeting the approved guidelines and 1121 forms?


Appendix C: Carton Pallet Loading – Standards Intercontinental Carton Sizes


Appendix D: Quick Reference Guide

Do Deviation Don’t

Co

nta

ine

r

Choose a standard container or IMC carton

size

Use recyclable materials

Insure weight limits are not exceeded for manually

handled containers 12 kg

Insure packaging will protect part quality

Insure the appropriate

strength material is being used

Films, plastic bags and foam sheets should be

avoided if possible

Wax coated paperboard or corrugated should not be

used unless required

EPS foam (polystyrene) should not be used

Foam glued to corrugated

should not be used

Un-recyclable materials should not be used

Pa

lle

t

Insure proper pallet size is being used,

Maximum 1200 x 1000 mm

Insure your Solid Wood Packaging is ISPM 15 Certified and marked

accordingly

Alternate size pallets should only be used when required due to part size.

Corrugated, molded pulp, plywood, particle board,

laminate and metal pallets should only be used if a treated alternative is not

available

There should be no protruding objects or sharp

edges on the pallets

Sh

ipp

ing

Un

it L

oad

Overall design should allow for the best space utilization

possible

Shipping Unit Load Height should not exceed 1100 millimeters or 43 inches

Insure that your stretch wrap/plastic banding is

being used properly

Make sure your 1121 form is submitted and approved

via the PICS website

Any use of wood supports should be minimized or replaced with paper or

corrugated material

Confirm acceptance of any deviations in writing

Wood crates should not be used

Do not use any nails,

staples, or metal banding to attach large cartons to the

pallet

No pyramid Pallet loads should ever be shipped

Pallet loads should have no

overhang

Excel based 1121 forms are no longer acceptable

visteon packaging guidelines. generals requirements and ......visteon packaging guidelines -...

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