May 4-8, 2015
Package Engineering
Supplier Training May 2015
Package Engineering
Web Page eSupplier Connect
Step 1. Go to http://esupplierconnect.com
Step 2. Select the logo representing which organization you want to
access (Fiat, Chrysler)
Step 3. Type in the appropriate S-id and Password
Step 4. Select Chrysler Group at the top
Step 5. Select Reference tab
Step 6. Scroll down and click on Mopar Package Engineering or
use search function
WELCOME TO OUR WEBSITE
https://ps.extra.chrysler.com/sites/mpe
***Review our website on a regular basis for new information***
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Package Engineering
Mopar Package Engineering Website
Please check regularly. Updates are made often.
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Package Engineering
Commodity Breakdown
Gina Kreiner
586-497-0287
Mike McGraw
586-497-1001
Tim Smalley
586-497-7333
GI26@chrysler.com
Mike.mcgraw@
external.fcagroup.com
Tim.smalley@
external.fcagroup.com
Eric Crumpton
586-755-6861
Kin Yu
586-497-4736
Carl Villanueva
586-497-1638
EC780@chrysler.com
Kin.wahyu@
external.fcagroup.com
Carl.villanueva@
external.fcagroup.com
The full commodity breakdown is viewable through the “Contact Information”
link on the left of the homepage.
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May 4-8, 2015
Packaging Types
Packaging Types
Methods of Packaging
• As a supplier to Mopar, you have the option to package service parts 1 of 2
ways
• Unitized (1 part per package or MSQ)
• Bulk (multiple pieces per package)
Unit Pack
Bulk Pack
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Packaging Types
Bulk Packaging
What is bulk packaging?
•
•
•
Multiple parts shipped in one container (i.e. 5 parts in one box)
092A: Referenced in PentaSAP
Requires 856 Miscellaneous charge ASN
Where do you ship bulk packaged parts?
1.
A Mopar Third Party Packager (3PP) to be unit packed
OR
2.
Directly to a Mopar depot in bulk packaging – doesn’t require individual unit
packaging
What are the bulk packaging quantity guidelines?
•
•
Mopar standards call for no more than 3 months worth of inventory
Order increments can be added to your contract
• These will allow parts to be released in multiples of a specified quantity every
time
• For example, an order increment of 5 pieces will generate releases in quantities
of 5, 10, 15, etc.
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Packaging Types
Bulk Packaging to 3PP
Shipping Directly to Third Party Packager (3PP)
Packager
Locations
03116
03118/03119
40988
60989
90990
•
All Parts
Does not exceed more than 3 months
worth of forecasted volume
•
Production backup option
•
Pallets
• Heat treated
• 4 way entry
• No winged
• No overhang
•
Standard shipping labels
• AIAG, etc.
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Packaging Types
Bulk Packaging to Mopar Depot
Shipping Directly to Mopar Depot
Small Parts
•
•
If parts are too small for individual labels,
labeling is not required to appear on the
part (shipped loose)
• Parts include: nuts, bolts, etc.
All labels will remain on the outer container
• AIAG shipping label, master pack,
destination labels, etc.
No individual label
Large Parts
•
•
These parts must be durable enough to withstand final
shipment to dealerships
**Must be individually labeled using Mopar Lseries Label in accordance with the I-20 Standard**
• Barcodes that do not scan or scan improper
information will result in a non-conformance
ticket
Placing label directly on
the part
Wire tag with label
affixed to the tag
I-20 Standard - Outlines the labeling requirements for Mopar available on Mopar
Packaging Website: https://ps.extra.chrysler.com/sites/mpe
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Packaging Types
Unitized Packaging
Unitized Packaging
•
•
•
Placing one part in a carton, bag or other container or MSQ
Container must be labeled with Mopar Unit Label (L-Series)
All unit labels/master pack labels must be purchased through Mopar’s single source
label supplier, RR Donnelley
• moparlabels@rrd.com
A unit/primary container is considered anything that directly:
• Protects and conceals
• Identifies a product for final handling and distribution
**Keep in mind that a polybag may be considered a primary container OR dunnage,
depending on its use**
Part
Unit Pack
Polybag Unit
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Packaging Types
Unitized Packaging
Secondary/Master Containers
•
Secondary containers can be used to contain several
unit packs (also called master containers)
•
Often used when unit packs are small, have low
stacking strength, or when a unit pack is a polybag,
flexible, retail pack, etc.
•
Secondary containers are not always needed
Part
Unit Pack
Secondary
Container
Pallet Load
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May 4-8, 2015
Labeling
Labeling
Unitized Labeling Standard
I-20 Standard
• Outlines the labeling format for identifying unitized and secondary
containers that are packaged for Mopar
• View website for standard details
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Labeling
Mopar L-Series Unit Labels
Current Labels
•
•
Without Double
Codification
•
•
Standard label sizes:
L-6060: 60mm x 60mm
L-6045: 60mm x 45mm
With Double
Codification
One label is required per unit container.
Fascias, bumpers, and other oversized commodities require one unit label on
each end of the container.
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Labeling
Double Codification Format
2015 2nd Quarter Requirement:
Packaging labels must support two part numbers.
Must be 13 digits
10 digit part number + 3 digit qty
Must be
secondary part
number. Will be
provided via 830
EDI LIN segment
Quantity
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Labeling
Single Source Label Supplier
• All labels for unit packed parts must be purchased through Mopar’s single
source label supplier, RR Donnelley – moparlabels@rrd.com
• Labels must be printed on a thermal transfer printer
• Insures that barcodes are machine readable
• RR Donnelley will print complete labels for an incremental fee
Failure to comply WILL result in a non-conformance ticket issued to your location
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Labeling
Miscellaneous Labels
•
Heavy Part Label
•
•
•
•
Prop 65 Warning Label
•
•
•
Required for unit packed parts where Mopar has added core/deposit charges
Use in addition to standard unit label
Performance Part Label
•
•
•
Required for brake cartons and brake kits
Use in addition to standard unit label
Deposit Part Label
•
•
•
Required for unit packs weighing over 30 pounds
Not individually palletized
Use in addition to standard unit label
Required for all performance parts
This replaced the standard unit label used on performance parts
LeafMark Part Label
•
•
Required for unit packed brake friction products in accordance with the Better Brake Rule
Use in addition to standard unit label
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May 4-8, 2015
Palletization
Palletization
Pallet Requirements
• Outlines:
•
•
•
•
•
Pallet load requirements
Dimensional footprints for each PDC
Mixed loads requirements
Load label requirements
Max load height for standard pallet loads (< 48” in length) is 33” high
for all Mopar depots
• All loads shipped to Mopar must comply with the pallet
requirements
• All deviations must be pre-approved by Package Engineering
• An updated version of this document has been published on the
website: Palletization Criteria
https://ps.extra.chrysler.com/sites/mpe
Unapproved deviations will result in a non-conformance
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Palletization
Pallet Requirements
Standard Pallet Sizes (Height Includes Pallet)
•
•
•
•
•
•
Location 03110 (Center Line)
Location 03111 (Warren)
Location 03129 (Milwaukee)
Location 03189 (Mexico)
Location 03117 (Sherwood)
All Other Mopar Locations
= 42” x 48” x 33”
= 42” x 48” x 33”
= 42” x 46” x 33”
= 42” x 48” x 33”
= 42” x 48” x 33”
= 42” x 48” x 33”
• Containers that are > 48”, should utilize longer pallets, all pallets should be sized
to container length. Containers cannot overhang the pallet
• All pallet shipments to Mopar facilities must be:
• Heat treated
• Flush (no winged pallets)
• 4-way entry with bottom deckboards
Incorrect pallets will be subject to Non-Conformance Tickets
Mopar pallet specifications can be found on the website
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Palletization
Pallet Requirements
Max:
42”
Max:
48”
Max:
33”
Incorrect shipping
loads will be subject
to Non-Conformance
Tickets
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Palletization
Pallets: “Wings”
CORRECT: Flush
No “Wings”
INCORRECT:
“Wings”
Incorrect pallets will be subject to Non-Conformance Tickets
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Palletization
Pallets: Overhang
CORRECT: No Overhang
INCORRECT: Overhang
Incorrect pallets will be subject to Non-Conformance Tickets
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Palletization
Pallets: 4-Way Entry
Heat treated pallet must
follow ISPM 15 Standard
CORRECT: 4-Way Entry
INCORRECT: 2-Way Entry
Not an entry
Incorrect pallets will be subject to Non-Conformance Tickets
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Palletization
Parcel Shipments
DO NOT ship small single containers on a pallet
Use your parcel shipment provider as your shipping method
Mopar Helpline: 888-303-0033 or mopar_helpline@ryder.com
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Palletization
Returnable Packaging
• Returnable packaging is used for A-surface
sheet metal that ships into the Marysville
Source Warehouse (03116) to be e-coated
OR
• Remanufactured (REMAN) powertrain
transmissions/engines
• Standard containers should NOT be used
for shipments into our third party packagers
or a Mopar receiving location
• Mopar is investigating the possibility of
using returnable standard containers for
shipments into packaging facilities.
Significant obstacles will need to be
overcome to implement
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Palletization
Supplier Ship Direct: SSD
• When shipping parts directly to dealers, packaging must pass ISTA 3A testing to
withstand parcel shipments
• Be sure packaging is tested prior to shipment
• Documentation is often requested in order for Package Engineer to approve
• Over packing may be necessary depending on commodity
• In addition to your CDR submission, your Packaging Engineer may request
photos or samples to verify sufficient packaging
• Visit the UPS website for more information
http://www.ups.com/content/us/en/resources/ship/packaging/guidelines/how_to.html
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May 4-8, 2015
Graphics
Graphics
Mopar Branded Retail Packaging
•
Certain commodities require retail graphic
packaging
•
If you are currently packaging in this
method, it must be the most current graphic
level
•
Package Engineering will work with retail
packaging suppliers on running changes
•
Distributor statements with “Daimler” on the
packaging will be refused
•
Distributor statements with “Chrysler Group
LLC” and “FIAT” must be updated to the
proper “FCA” company name
Please Note: Mopar Graphic Packaging order quantities should not exceed six (6) months of release volume. Quantities above six (6)
months must be approved prior to purchase by Mopar Package Engineering. Mopar will not be responsible for excess or obsolete material.
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Graphics
Old Graphics and Decorative Cartons
All incoming decorative cartons should feature the
Fiat Chrysler Automobiles distribution statement
Please Note: Mopar Graphic Packaging order quantities should not exceed six (6) months of release volume. Quantities above six (6) months
must be approved prior to purchase by Mopar Package Engineering. Mopar will not be responsible for excess or obsolete material.
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Graphics
Corrugated Cartons
CORRECT: Current Graphics
INCORRECT: Old Graphics
* Note the old style Mopar logo
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May 4-8, 2015
Packaging Approvals
Packaging Approval
New Model Packaging Approval Process
• CDR (Container Design Request) is Mopar’s online packaging approval
process
• All packaging specifications and cost must be submitted for approval prior to
shipping parts
• This is used for new model parts and packaging changes
• Approvals are required for all unit and bulk shipments
• Packaging cost does not get approved through the WebRFQ system
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Packaging Approval
Submitting Dimensions and Weight
• The Mopar Warehouse Management System is based entirely on
dimensions and weight
• It is REQUIRED that when you are submitting your packaging information,
that the dimensions and weight are 100% accurate
• During the submission process you will be required to provide the UNPACKAGED and PACKAGED dimensions
• Metric (centimeters, grams) and US (inches, pounds) options are available
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Packaging Approval
Submitting Dimensions and Weight
• Length should be the longest dimension
• Width should be the second longest dimension, perpendicular to the length
• Depth/Height is the smallest and last remaining dimension
• If your part is coiled or folded, please use the coiled or folded
dimensions (i.e. wiring, seat covers)
• Failure to comply and/or submission of inaccurate information WILL result in
a non-conformance ticket issued to your location
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Packaging Approval
Scenarios Requiring Packaging Approval
Scenario
Current Part
Number
New Part
Number
Packaging
Cost
New Model
Part
NEW
12345678AA
New
Nic-up Part
12345678AA
12345678AB
Carryover from
Previous
Change Notice
(CN)
12345678AA
87654321AB
Possible price
change
Packaging
Change
12345678AA
12345678AA
Cost savings
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Packaging Approval
Approval Process
***FYI***
• Please allow 30 calendar days for packaging submissions to be reviewed
• Packaging costs can not be added to the contract header until the contract has been
placed
• All BOR/VOR shipments take priority, so please be sure to alert your packaging
engineer if these apply
• If packaging is approved for a part and there is a change in the contract number,
please email Package Engineering to add packaging to the new contract
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Packaging Approval
Starting the Approval Process
• For new model parts, send an email to Package Engineering
(mpe@fcagroup.com) with a subject of “CDR Quoting”
• Required information
• Part number(s) to quote packaging specification
• 5 digit supplier code and location code (if applicable)
• Email addresses of required contacts (for access to system)
• Contract number
• ONLY include the required information
• No attachments or other information
• Emails in the incorrect format will not be reviewed
• Do NOT copy (CC) your Package Engineer on the email
• “TRM” is used as a place holder for all trim colors
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Packaging Approval
New Model Packaging Approval Process
Supplier sends required information to
mpe@fcagroup.com
Supplier receives email indicating assigned work
Supplier completes and submits web form for
approval
Package Engineering approves
Package Engineering disapproves
Supplier receives generated email indicating
approval
Supplier receives generated email indicating
disapproval
Supplier’s contract is updated
Revise specifications/cost
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Packaging Approval
Approval Process
• Standard packaging
information must be
completed and submitted
• Regardless of packaging
method (unitized or bulk),
you will be prompted to fill
out how you are
packaging your part along
with all associated
packaging costs
Measurements of Metric (centimeters, grams) and US (inches, pounds)
options are available
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Packaging Approval
Approval Process
After all required
information is entered,
select the submit button to
sent to your package
engineer for review
•
•
•
Mopar reserves the right
to request
invoices/quotes to
validate cost
All packaging approvals
are subject to review
All current packaging
costs are subject to
review
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Packaging Approval
Approval Process
Approvals
If there are no issues or concerns with your proposed packaging and cost, an email
will be generated indicating an approval
• The generated approval is what is required to PPAP
• Disapprovals also generate an email along with a reason given by your
packaging engineer
Approved packaging costs will be added to your contract
Packaging Spot Buy Requests
It is the responsibility of the supplier to monitor payments and proactively address
any issues. Standard policy outlines that issues will be reviewed within a rolling 12
month period. Aged requests will require escalation in order to be considered.
Sincerely,
Mopar Purchasing & Packaging
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Packaging Approval
CDR Useful Features
Features
•
Automatic Approvals
• Use the “Copy Packaging” function and select “Same Packaging and Same
Cost” if an approved specification is moving to the next revision level and
packaging is not changing (12345678AA  12345678AB)
• Please allow 5 business days for your packaging engineer to update the
existing contract with the approved cost
•
Adding Attachments
• Photos, invoices and other attachments can be added to CDR submissions
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Container Design Request: CDR
Enforced CDR Requirements
CDR now requires the following information
• Contract Number
• Use the TRM contract number for parts with three digit color codes
•
Is any packaging cost included in material- should be called out as a 198
• Options Include: All, Some, or None
•
What is the 198 price?- Expendable packaging cost included in material cost
Starting Q4 2015 – Packaging information will be fed directly from CDR to SAP.
If the provided part number, contract, currency, or 198 are inaccurate, the contract will not
update and the approved CDR will be sent back for corrections.
Packaging Approval
Selecting a Method of Packaging
Does the part
require unit
packaging?
Yes
Do you have the
capabilities to unit pack?
(Proper labels, pallets,
etc.)
No
No
Yes
Individually Labeled
Unit Part
TO DO:
• Submit CDR
• I-20 Standard
• Pallet Req.
Non-Labeled Bulk Part
TO DO:
Submit CDR
Is the part large
enough to fit a
label?
No
Yes
Individually
Labeled Bulk Part
TO DO:
• Submit CDR
• I-20 standard
• Pallet Req.
All proposed packaging
quantities cannot exceed 3
months’ worth of the projected
forecast–check releases
Non-Labeled Bulk
Part
TO DO:
• Submit CDR
• Pallet Req.
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First Time Receipt
Areas of Focus
Implement initial part validation process at first time receipt of material to ensure parts are
set up correctly for Mopar Supply Chain
Packaging
Verify packaging
specification
Collect weights and
dimensions
Label compliance
Confirm correct
graphics
Hazmat and
Regulatory
Confirm Country
of Origin
Check Hazmat
and DOT
markings
Review shelf life
Storage
Quality
Marketing
Validate storage
criteria
Home Base
designation
Verify NLC
(national stocking)
assignment
Verify PPAP or
IAA compliance
Check part
marking
Check parts for
appearance,
color, texture, L/R
hand
Identify any nonconformances
Capture part
photographs for
EPC, digital
marketing and
eCommerce
applications
Check for damage
FIRST TIME RECEIPT PROCESS –
Launch began in September 2014 limited scope
Full launch occurred January 2015 for all New Model parts
All parts will be
professionally
photographed
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First Time Receipt
Material Flow
A. Service Unique
• Accessories
• Performance Parts
• Campaigns / Field
Actions / RRTs
• Supplier Resourcing
Integrate with Service PPAP
• Integrate First Time Receipt process into existing
Service PPAP
• Perform initial part validation for Packaging,
Regulatory and Storage requirements
• Launch September, 2014
• Service CN Activity
B. Common to
Production
• Production End Item
• Serviceable
• Components
Production CN Activity*
*requirements TBD
Implement First Time Receipt
• Contract with Exel to perform First Time Receipt
(short term) during inbound logistics process
• Flag parts for release to FTR at New Model Parts
Set-up
• Perform initial part validation for Packaging,
Regulatory, Storage and basic Quality requirements
• Launch beginning in September, 2014
C. Exceptions
• Sheet Metal, wheels
• Engines /
Transmissions
• Large, Bulky Parts –
frames, axles, glass
Modified First Time Receipt
• Develop a modified First Time Receipt process for
large, bulky parts
• Further discussion required
• 1st quarter 2015
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First Time Receipt
Benefits & Advantages
•
•
•
•
•
•
•
•
•
Validate supplier’s packaging specifications which will reduce nonconformance
and potential damage to the package and part
Reduce warehouse labor to resolve inbound error location conditions (dims,
wrong home base, wrong NLC, etc.)
Reduce mis-picks and ensure proper labeling and bar code scanning on all
parts
Reduce transportation dollars for re-location of stock to the correct National
PDC
Ensure regulatory compliance and prevent potential DOT related fines
Ensure timely customs clearance with correct weights and dimensions, and
correct country of origin for all global shipments
Prevent customer dissatisfaction by correcting part quality issues prior to
releasing to the network (wrong part in box, missing components, wrong color,
part markings, etc.)
Better control on all new model launches
Enable marketing efforts to collect photos of parts for catalogs and websites
that could result in increased sales
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May 4-8, 2015
Invoicing and Releases
Invoicing and Releases
SAP: Invoicing
• Reference EDI manual for packaging invoicing
• Bulk Packed Parts (092A)
• Packaging cost must be on ITA segment of EDI 856 (ASN)
• The EDI 810 Miscellaneous Charge process no longer exists (subsequent
submission of additional charges)
• Container 00000EXP
• Mopar 092A expendable packaging costs should use 092A on the ASN record
• ERS and Non-ERS receiving locations require an 092A ASN
• Failing to ASN will result in no packaging payment
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Invoicing and Releases
Packaging Releases
• Minimum Order Quantity: Set by Purchasing
• Order Increment Quantity/Standard Pack Size: Set by Packaging
• These amounts must be reviewed and approved by package
engineering, inventory control, and purchasing
• Typical quantities are not to exceed your 3 month forecast
• Should be either a full carton, full layer, or full pallet load
(based on demand)
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May 4-8, 2015
Non-Conformance
Non-conformance
The Focus
• Quality
• Packaging is the “face” of Mopar to the customer
• Eliminate damaged/poor quality packaging
• Standardization
• Avoid similar commodities packaged in different containers
• Avoid multiple ship to locations (STL’s)
• Consistent Mopar brand image
• Compliance
• Enforcing requirements
• Non-Conformance Tickets (NCT’s)
• Inspectors at each NPDC
• Rework charge for repackaging
• Closed NCT’s will affect supplier rating
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Non-Conformance
Non-Conformance Tickets
Packaging NCT Examples:
•
Issued on inbound
• Dims and weight
• Pallets
• Spec violation
• Graphics
• Compromised Packaging
• Labeling
• Bar code must be able to be read by a scanner
• Proper use of the company name (FCA US LLC)
• Mopar labeled and branded products must reflect the official
company name: FCA US LLC
• Print containing Daimler Chrysler or Chrysler LLC are not compliant
and will result in a NCT
Quality NCT’s
•
•
For quality NCT questions contact mopar_sq@fcagroup.com
An NCT overview class is also offered during supplier training week
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Non-Conformance
Non-Conformance Tickets
Charges for Closed Non-Conformance Tickets
Administration Fees
• 2 Hours - Depot Administration (writing ticket)
• 4 Hours - Mopar Packaging Engineering Administration (investigation)
*** 6 hours non-negotiable***
Repackaging Fees
• Re-packaging material cost
Depot Labor Fees
• Re-work hours
For specific system inquiries, request a trouble ticket via eSupplierConnect
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For further questions contact your Package
Engineer or visit us at
https://ps.extra.chrysler.com/sites/mpe/
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