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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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 2 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 3 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 4 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 5 of 126
• 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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 6 of 126
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
NAMC review / approve
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 7 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 8 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 9 of 126
G. Packaging Operations – Roles & Responsibilities <SOP to Build Out>:
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 10 of 126
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
Network Communication):
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
Supplier Responsibility:
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
Network Communication):
Region Changes
- Period change over packet:
Volume File
Ship Point
Location Change
NAMC Pkg
(from TEMA
Log)
NAMC Pkg
SCNC Packet (Supply Chain
Network Communication):
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.
Supplier Responsibility:
Procure (if not purchased direct from Toyota
Party ) , receive & insert returnable
packaging into system at time of change
implementation.
Toyota Party Responsibility:
Authorize labels.
Supplier Responsibility:
Procure, receive and apply new labels /
stencils to all returnable packaging in the
system by SOP of new ship location.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 11 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 12 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
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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.
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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.
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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-F F: Flat bottom 610 381 191 NSO2415-7M NF241507AS Adjacent
ST241507 610 381 191 NSO2415-7R NF241507AP Adjacent
ST241511-F F: Flat bottom 610 381 280 NSO2415-11M NF241507AS Adjacent
ST241511 610 381 280 NSO2415-11R NF241511AP Adjacent
ST241514 610 381 368 SO2415-14R NF241514AP Adjacent
ST242207-F F: Flat bottom 610 572 191 NSO2422-7M NF241514AS 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
SF241511 n/a 610 381 280 n/a CF241511AP Adjacent
SF241514 n/a 610 381 368 n/a CF241514AP Adjacent
SF242207 n/a 610 572 191 n/a CF242207FP Adjacent
SF242211 n/a 610 572 280 n/a CF242211FP Adjacent
SF242214 n/a 610 572 368 n/a CF242214FP Adjacent
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 16 of 126
Straight Wall Tote Folding Tote Incorrect Size & Color Corrugated Plastic Tote
Standard Handheld Container (tote) Nonstandard Handheld Container (tote)
Straight Wall Tote Folding Tote Incorrect Size & Color Corrugated Plastic 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)
Straight Wall Tote Folding Tote Incorrect Size & Color Corrugated Plastic 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
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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
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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
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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
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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
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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
SR4548HH-W48 45x48 Walk in rack on 48 side 1156 1232
SR6048HH 60x48 Rack 1537 1232
SR6048HH-W60 60x48 Walk in rack on 60 side 1537 1232
SR6048HH-W48 60x48 Walk in rack on 48 side 1537 1232
SR6096HH 60x96 Rack 1537 2452
SR7548HH 75x48 Rack 1918 1232
SR7548HH-W75 75x48 Walk in rack on 75 side 1918 1232
SR7548HH-W48 75x48 Walk in rack on 48 side 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
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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
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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
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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.
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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)
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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
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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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
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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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 29 of 126
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:
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 30 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 31 of 126
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.
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October, 2015 Manufacturing North America Page 32 of 126
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
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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
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October, 2015 Manufacturing North America Page 34 of 126
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
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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)
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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
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
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
generated to complete an
operation where the force can
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)
Measure should reflect as
closely as possible
production conditions such as
time required to complete &
line of force
Push or pull with
both hands or palms
Push force that must be
generated to complete an
operation where the force can
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)
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
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.
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.
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.
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.
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 37 of 126
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)
Measured from the standing
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
Measured from the standing
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 38 of 126
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
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October, 2015 Manufacturing North America Page 39 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 40 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
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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
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October, 2015 Manufacturing North America Page 42 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 43 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 44 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 45 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 46 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 47 of 126
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/Supplier N-5
Fabricator N-5
TEMA Pur N-5
Fabricator/Supplier N-2
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 48 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 49 of 126
TMMC Packaging claim cover sheet (Also in VPACS Documentation):
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 50 of 126
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.
Purchase & Design Packaging to
ensure integrity of parts or materials
during transit. The packaging may be
returnable or expendable.
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.
Negotiates purchase price (including
packaging cost) of Level I components
with Tier II.
Will be the intermediary for
commercial issues between the Tier I
and Tier II.
Negotiates purchase price (including
packaging cost) of Level I components
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 51 of 126
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.
#
Returnable Packaging
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
Supplier 100% responsible to purchase any necessary
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.
# Days in transit from:
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
Example Calculation:
# Day(s) Full + # Day(s) Empty + # Buffer Day(s)
-> Total # days allocated for NAMC internal process.
*Exact quantity dependent on multiple factors such as pick up &
delivery frequency. NAMC will calculate detail quantity allocation.
NAMC Packaging
Supplier
1
4
3
2
5
6
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 52 of 126
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
returnable packaging
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
returnable packaging
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
returnable packaging
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 53 of 126
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 54 of 126
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
Via email and phone:- Supplier Name
- Supplier Code
- Issue Type
- Part number
- Issue Rank
Forward email that was
sent to the Specialist.
Address A/M with same request.
Via email and phone:- Supplier Name
- Supplier Code
- Issue Type
- Part number
- Issue Rank
Forward email that was
sent to the Specialist & A/M
Address Mgr with same request.
Via email and phone:- Supplier Name
- 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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 55 of 126
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 S or A: 1 Day; Rank E: 2 Day;
Rank B: 5 Days
Rank S or A: 1 Day; Rank E: 2 Day;
Rank B: 5 Days
Rank S or A: 1 Day; Rank E: 2 Day;
Rank B: 5 Days
Rank S or A: 1 Day; Rank E: 2 Day;
Rank B: 5 Days
Rank S or A: 1 Day; Rank E: 2 Day;
Rank B: 5 Days
Rank S or A: 1 Day; Rank E: 2 Day;
Rank B: 5 Days
Rank S or A: 1 Day; Rank E: 2 Day;
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 56 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 57 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
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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
NAMC review / approve
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
NAMC review / approve
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 59 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 60 of 126
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”)
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 61 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 62 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 63 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 64 of 126
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”.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 65 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 66 of 126
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$
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 67 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 68 of 126
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 #:
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
PACKAGING TRIAL SHIPMENT SHEET
Part Number:
Pkg Contact Phone
#:
NAMC Pkg Contact:
Trial Description: "HVAC Rack Pkg Trial"
Enter Contact #
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 69 of 126
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
Toyota Party Responsibilities
Send result of trial.
Decide PPF design roles.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 70 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 71 of 126
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
Toyota Party Responsibilities
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”.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 72 of 126
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):
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 73 of 126
#
Returnable Packaging
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
Supplier 100% responsible to purchase any necessary
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.
# Days in transit from:
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
Example Calculation:
# Day(s) Full + # Day(s) Empty + # Buffer Day(s)
-> Total # days allocated for NAMC internal process.
*Exact quantity dependent on multiple factors such as pick up &
delivery frequency. NAMC will calculate detail quantity allocation.
NAMC Packaging
Supplier
1
4
3
2
5
6
.
.
.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 74 of 126
H. Packaging Readiness
Toyota Party Responsibilities
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 75 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 76 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 77 of 126
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
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 78 of 126
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
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)
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
a. If Yes, specify date and shipment # of the day Date / Shipment #:
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.
)
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 79 of 126
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
Impact to Parts Shipment A 1 Day Rack shortage w/ no expendable packaging (back-up) available, etc.
No Impact to Parts Shipment B 5 DaysReturnable packaging shortage w/ expendable packaging (back-up) available, excess containers,
reimbursement follow up, etc.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 80 of 126
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
Impact to Parts Shipment A 1 Day Rack shortage w/ no expendable packaging (back-up) available, etc.
No Impact to Parts Shipment B 5 DaysReturnable packaging shortage w/ expendable packaging (back-up) available, excess containers,
reimbursement follow up, etc.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 81 of 126
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).
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 82 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 83 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 84 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 85 of 126
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).
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 86 of 126
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).
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 87 of 126
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).
Type Items Procedure Good No Good
Clean racks Maintain the cleanness of rack.
Structural defectsCheck for any structural frame being bent,
cracked or distorted.
Welds Check for wear, cracks, and distortion.
Dunnage Check for wear, missing dunnage.
Kanban holdersCheck for damage, missing holders,
missing plastic pouch.
Gates/Lids
Open lids/gates and check for the smooth
movement. Ensure the hydraulic piston
hold the lid in open position.
Cables
Check for frayed cable. Ensure the locking
pins and connections are secured to the
cable.
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.
HingeCheck for tightness, presence of hinge
bolts.
Hold downCheck for missing hold down, wear on
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 88 of 126
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).
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 89 of 126
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
DO NOT USE UNTIL REPAIRED.
NAMC
NAMC
Weld
Hinge
Lock
Shock
Gate
Handle
Foot
Door
KB Holder
Other
Damage Type
Damage Location
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 90 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 91 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 92 of 126
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
copy of
DPR
No
Yes
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 93 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 94 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 95 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 96 of 126
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.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 97 of 126
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):
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 98 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 99 of 126
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”.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 100 of 126
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
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October, 2015 Manufacturing North America Page 101 of 126
3. Folding post
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 102 of 126
11
GA
2
"x2
"
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October, 2015 Manufacturing North America Page 103 of 126
B. Steel Rack Drawings; Section 3.0.H.7.f
1. Standard base
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2. Drawing template
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Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 106 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 107 of 126
C. Quantity Allocation Visualization; Section 3.0.K.1
#
Returnable Packaging
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
Supplier 100% responsible to purchase any necessary
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.
# Days in transit from:
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
Example Calculation:
# Day(s) Full + # Day(s) Empty + # Buffer Day(s)
-> Total # days allocated for NAMC internal process.
*Exact quantity dependent on multiple factors such as pick up &
delivery frequency. NAMC will calculate detail quantity allocation.
NAMC Packaging
Supplier
1
4
3
2
5
6
.
.
.
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 108 of 126
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:
Logistics Carrier: Logistics Carrier Phone #:
Logistics Carrier: Logistics Carrier Phone #:
DO NOT FOR USE PRODUCTION
PACKAGING TRIAL SHIPMENT SHEET
Part Number:
Pkg Contact Phone #:
NAMC Pkg Contact:
Trial Description: "HVAC Rack Pkg Trial"
Enter Contact #
PACKAGING TRIAL SHIPMENT SHEET
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 109 of 126
E. Packaging Shortage & Reimbursement; Section 3.3.B.2
1. Process flow (all NAMC’s except TMMC)
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 110 of 126
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?
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
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)
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
a. If Yes, specify date and shipment # of the day Date / Shipment #:
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.
)
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 111 of 126
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
returnable packaging
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
returnable packaging
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
returnable packaging
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 112 of 126
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)
Dock Code 2: Expendable/Alternative Container Shipped 0 0 0
Beginning Delivery Order Number (DON)
Ending Delivery Order Number (DON)
Dock Code 3: 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
Beginning Delivery Order Number (DON)
Ending Delivery Order Number (DON)
Dock Code 2: Cardboard Lid Shipped 0 0 0
Beginning Delivery Order Number (DON)
Ending Delivery Order Number (DON)
Dock Code 3: Cardboard Lid Shipped 0 0 0
Beginning Delivery Order Number (DON)
Ending Delivery Order Number (DON)
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
Beginning Delivery Order Number (DON)
Ending Delivery Order Number (DON)
Dock Code 2: Wooden Skid Shipped 0 0 0
Beginning Delivery Order Number (DON)
Ending Delivery Order Number (DON)
Dock Code 3: Wooden Skid Shipped 0 0 0
Beginning Delivery Order Number (DON)
Ending Delivery Order Number (DON)
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 113 of 126
H. Daily Rack Inspection Check Sheet; Section 3.3.F.2.b
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.
DAILY RACK INSPECTIONV
ISU
AL
IN
SP
EC
TIO
NF
UN
CT
ION
AL
IN
SP
EC
TIO
N
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 114 of 126
I. Bi-Annual Rack Certification Check Sheet; Section 3.3.F.2.c
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 115 of 126
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
Type Items Procedure Good No Good
Clean racks Maintain the cleanness of rack.
Structural defectsCheck for any structural frame being bent,
cracked or distorted.
Welds Check for wear, cracks, and distortion.
Dunnage Check for wear, missing dunnage.
Kanban holdersCheck for damage, missing holders,
missing plastic pouch.
Gates/Lids
Open lids/gates and check for the smooth
movement. Ensure the hydraulic piston
hold the lid in open position.
Cables
Check for frayed cable. Ensure the locking
pins and connections are secured to the
cable.
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.
HingeCheck for tightness, presence of hinge
bolts.
Hold downCheck for missing hold down, wear on
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 116 of 126
J. Damage Repair Tag; Section 3.3.F.4.a
TOYOTA
DAMAGED CONTAINER
DO NOT USE UNTIL REPAIRED.
NAMC
NAMC
Weld
Hinge
Lock
Shock
Gate
Handle
Foot
Door
KB Holder
Other
Damage Type
Damage Location
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 117 of 126
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:
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 118 of 126
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:
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 119 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 120 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 121 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 122 of 126
N. TMMC Challenger ASN; Section 3.3.H.14.b
Load at Location ATTENTION: Denise Moreau x2259
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)
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 123 of 126
O. TMMC Challenger Bill of Lading; Section 3.3.H.14.b
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 124 of 126
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 125 of 126
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
Issue # 3 Revision 1 Toyota Motor Engineering & Chapter 3
October, 2015 Manufacturing North America Page 126 of 126