DENSO Supplier Labeling Policy

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Presentation transcript:

DENSO Supplier Labeling Policy Ace Sakakibara NAPC Sr. Mgr Paul Rush NAPC Mgr NAPC Section Leader Jason Hoekstra Document # NAPSLPS001 Rev. Revised Date NA Issue Date 12/11/15 DENSO Supplier Labeling Policy Purpose: The objective of this policy is to ensure the incoming material is labeled with the correct part number and traceability to manufacturing lot is maintained. Product received with incorrect part number on the label causes considerable issues for our manufacturing lines and in many cases DENSO’s OEM customers. Scope: This requirement applies to the labeling of the supplier product with the DENSO required Shipping Label. DN145 MX14.. Match

Table of Contents Section Item Pages 1.0 3 2.0 4 3.0 5-6 4.0 7-11 5.0 Ace Sakakibara NAPC Sr. Mgr Paul Rush NAPC Mgr Jason Hoekstra NAPC Section Leader Document # NAPSLP001 Rev. Revised Date NA Issue Date 12/11/15 Table of Contents Section Item Pages 1.0 Definitions 3 2.0 Supplier Labeling Policy Summary 4 3.0 Level 1: Manufacturing Line Side Labeling (Electronic Confirmation) 5-6 4.0 Level 2: Manufacturing Line Side Labeling (Manual Confirmation) 7-11 5.0 Level 3: Warehouse Labeling (Electronic Confirmation) 12-16 6.0 Level 4: Warehouse Labeling (Manual Confirmation) 17-21 7.0 Repack Requirements 22-23 8.0 Labeling Specifications 24-25

Definitions: 1.0 Definitions Page 3 of 25 Manufacturing Line Side Labeling – Process of apply DENSO Shipping Label to product at manufacturing line. This is preferred area to apply shipping label. Warehouse Labeling: Process of apply DENSO Shipping Label in warehouse. Manufacturing Electronic Confirmation: Process of using Computer program to validate that parts made in manufacturing match shipping tag. Warehouse Electronic Confirmation: Process of using computer program to validate Supplier Label matches DENSO Label through scan confirmation. Program Control Logic(PLC): Manufacturing Computer program used to confirm parts match shipping label and automatic print DENSO Shipping Label. NASWEB: DENSO Order Website for supplier to receive Purchase Orders, Label Formats, and send ASN(Advance Shipping Notices). Inspection Manuals: Manual to confirm key quality check points for product quality inspection. Management Layered Audits: Standard Audit system designed to ensure by several different levels of management that standardize processes are being followed.

2.0 Supplier Labeling Policy Summary Page 4 of 25 2.0 Supplier Labeling Policy Summary Requirement: Each Supplier must pick a Labeling Level and maintain the requirement for that level. In the event the Supplier cannot manage the labeling correctly DENSO will require the supplier to move up a level. <Supplier Labeling Levels> Level Description Details 1 Manufacturing Line Side Labeling (Electronic Confirmation) Manufacturing PLC(program logic control) electronically verifies correct part # & Quantity which triggers DENSO label printing (one for one) 2 Manufacturing Line Side Labeling (Manual Confirmation) DENSO Label is applied at the end of the production line with a double check. 3 Warehouse Labeling (Electronic Confirmation) Scanning Confirmation between Supplier label and DENSO Label. 4 Warehouse Labeling (Manual Confirmation) Manual confirmation of Supplier and DENSO Label. = DENSO Preferred Level * = DENSO Minimum Level <Overall Summary for Each Level> Legend Manufacturing Labeling Warehouse Labeling Requirements O = Required, - = Not Required Level 1 Electronic Level 2 Manual Level 3 Electronic Level 4 Manufacturing Label Generation and Control O - Start-up & Changeover Control Production Packing Log Quality Inspection- Part Matches Label WH Label Apply Process NA Quality Inspection – Part Matches Label MGMT Management Layered Process

3.0 Level 1 Manufacturing Line Side Labeling Electronic Verification Page 5 of 25 3.0 Level 1 Manufacturing Line Side Labeling Electronic Verification Level 1 Manufacturing Line Side Labeling Electronic Verification Level 1: Manufacturing Line Side Labeling (Electronic Confirmation) = DENSO Preferred Level

3.1 Level 1 Manufacturing Line Side Labeling Electronic Verification Page 6 of 25 3.1 Level 1 Manufacturing Line Side Labeling Electronic Verification Example EDI Order Processing Confirmation Steps: Scan Part Serial Number in PLC. PLC (Program Logic Control) Checks for Correct part # and quantity Once Container is full PLC prompts DENSO label to print. Container is labeled. Inventory is updated and serial numbers are recorded Scan Jig or Fixture Manufacturing PLC Or Part DENSO Label From DENSO Label Spec Benefits of Scanning of part label to generate shipping Label Eliminates need for pre-printed labels and relabeling at shipping. Shipping label is generated only after system confirms correct quantity and part #. Level 1 Requirements Item Requirements Label Generation and Control Electronic Scan to generate shipping label Electronic Traceability of label generation Start up / Change Over / Rotation / Shift Change Verification Special controls for new part runs are not required since PLC controls label generation. Production / Packing Inventory Management system with live updates Scan at point of production to log serial Inspection Secondary inspection of label part number match actual part in container is not required.

4.0 Level 2 Manufacturing Line Side Labeling Manual Verification Page 7 of 25 4.0 Level 2 Manufacturing Line Side Labeling Manual Verification Level 2 Manufacturing Line Side Labeling Manual Verification Level 2: Manufacturing Line Side Labeling (Manual Confirmation)

4.1 Level 2 Manufacturing Line Side Labeling Manual Verification Page 8 of 25 4.1 Level 2 Manufacturing Line Side Labeling Manual Verification Level 1 Manufacturing Line Side Labeling Electronic Verification Example Level 2 Requirements Item Requirements Label Generation and Control Labeling Sign-Out Log. Once Shipping Labels are generated from NASWEB a Sign-Out Log is utilized which is controlled by management to track the label issuing to manufacturing line. (See Example on Page 7) Key Information on Sign-out Log. Part Number, Qty of Labels Issued, Ship Date, Associate that printed the labels, and issue to line date. Start up / Change Over / Rotation / Shift Change Verification Changeover Check Sheet Key Items: First piece check includes label matches actual part, Validation of no old labels left at process, and only one part # at work cell at a time. (Example Page 8) Production / Packing 1) Production tracking log that tracks part number, lot number, production date, time, and DENSO Shipping Label serial number. 2) Production manuals posted at station which includes label validation. 3) Only one storage location at line for labels Inspection QC does 200% check which includes label validation and records result in inspection log by serial number (each tote) Inspection Manuals are posted at the line Management Layered Audits Key Point; Management must complete layered audits a minimum of one time per month to ensure processes are being followed.

4.2 Level 2 Manufacturing Line Side Labeling Manual Verification Page 9 of 25 4.2 Level 2 Manufacturing Line Side Labeling Manual Verification Level 1 Manufacturing Line Side Labeling Electronic Verification <Overall Level 2 Process> 1 Step 1 Label Generation and Control> Level 2 1 Labeling Sign-Out Log. Once Shipping Labels are generated from NASWEB a Sign-Out Log is utilized which is controlled by management to track the label issuing to manufacturing line. Key Information on Sign-out Log. Part Number, Qty of Labels Issued, Ship Date, Associate that printed the labels, and issue to line date. See Example Log Below. Purpose: Create Controlled Label Printing and Distribution method of DENSO Labels to prevent extra or mixed labels delivered to production line.

4.3 Level 2 Manufacturing Line Side Labeling Manual Verification Page 10 of 25 4.3 Level 2 Manufacturing Line Side Labeling Manual Verification Level 1 Manufacturing Line Side Labeling Electronic Verification <Overall Level 2 Process> 2 Step 2 Start Up/ Change Over/ Rotation/ Shift Change Verification> Level 2 2 Changeover Check Sheet Key Items: Purpose: Ensure no Part Mixing occurs during changeover, rotation, and or Shift Change. Confirm label control is handled as part as changeover. Example

4.4 Level 2 Manufacturing Line Side Labeling Manual Verification Page 11 of 25 4.4 Level 2 Manufacturing Line Side Labeling Manual Verification Level 1 Manufacturing Line Side Labeling Electronic Verification <Overall Level 2 Process> 3 4 5 Step 3 Production and Packing Level 2 3 Utilize Production tracking log that tracks part number, lot number, production date, time, and DENSO Shipping Label serial number. 2) Production manuals posted at station which includes label validation. 3) Only one storage location at line for labels Purpose: Ensure no Part Mixing or wrong Label applied at final pack-out. Step 4 Quality Inspection Level 2 4 QC does 200% check which includes label validation and records result in inspection log by serial number for each tote. See example below 2) Inspection Manuals are posted at the line Purpose: Ensure no wrong label applied by production and packing process 5 Step 5 Management Layered Audits Level 2 Key Point: Management must complete layered audits to ensure processes are being followed. (Example Leader Check Frequency (Line Leader – 2 times per week, Supervisor (1 time per week) , Plant Manager (1 time per month) Purpose: Ensure by several different levels of management that standardize processes are being followed and are working well for the associates

5.0 Level 3 Warehouse Labeling (Electronic Confirmation) Page 12 of 25 5.0 Level 3 Warehouse Labeling (Electronic Confirmation) Level 2 Manufacturing Line Side Labeling Manual Verification Level 3: Warehouse Labeling (Electronic Confirmation)

5.1 Level 3 Warehouse Labeling Electronic Confirmation Page 13 of 25 5.1 Level 3 Warehouse Labeling Electronic Confirmation Level 1 Manufacturing Line Side Labeling Electronic Verification Example <Electronic Confirmation of Shipping Label Part Number> Supplier Label GM12356 QTY = 4 DENSO Label <Manufacturing Labeling with Supplier Internal Tag> Item Requirements Change Over or Start-up Start up / Change Over / Rotation / Shift Change Verification *Changeover Check Sheet Key Items: First piece check includes label matches actual part, Validation of no old labels left at process, and only one part # at work cell. Production / Packing 1) Production tracking log that tracks part number, lot number, production date, and time. 2) Production manuals posted at station which includes label validation. 3) Only one storage location at line for labels Inspection QC does 200% check which includes label validation and records result in inspection log by serial number (each tote). Manuals are posted at the line. Note: If Manufacturing equipment 100% electronically verifies parts match label by vision system or part ID scanning than 200% check is not required. <Warehouse DENSO Label Apply Process> Item Requirements Label Generation and Control Labeling Sign-Out Log. Once Shipping Labels are generated from NASWEB a Sign-Out Log is utilized which is controlled by management to track the label issuing to shipping process. Key Information on Sign-out Log. Part Number, # of Labels Issued, Ship Date, Associate that printed the labels, and issue to shipping process date. Label Process Scan system exists that cannot be bypassed that electronically checks DENSO Label versus Supplier label. Labeling is one for one process. 1 Piece Check per Box 1 piece per DENSO Label is verified that part matches DENSO Kanban. Note: Not required if manufacturing equipment electronically verifies parts to label Management Layered Audits Key Point; Management must complete layered audits a minimum of one time per month to ensure processes are being followed.

1 1 Level 1 Manufacturing Line Side Labeling Electronic Verification Page 14 of 25 5.2 Level 3 Warehouse Labeling Electronic Confirmation Level 1 Manufacturing Line Side Labeling Electronic Verification <Overall Level 3 Process> 1 Manufacturing Process Warehouse Label Apply Change Over or Start-up Production / Packing Inspection Quality Inspection Management Layered Audit Apply Label Process Step 1 Change Over or Startup Level 3 1 Changeover Check Sheet Key Items: Purpose: Ensure no Part Mixing occurs during changeover, rotation, and or Shift Change. Confirm label control is handled as part as changeover.

Page 15 of 25 5.3 Level 3 Warehouse Labeling Electronic Confirmation Level 1 Manufacturing Line Side Labeling Electronic Verification <Overall Level 3 Process> Manufacturing Process Warehouse Label Apply 2 3 Change Over or Start-up Production / Packing Inspection Quality Inspection Management Layered Audit Apply Label Process Step 2 Production and Packing Level 3 2 Production tracking log that tracks part number, lot number, production date, time, and Supplier Internal Identification. 2) Production manuals posted at station which includes label validation. 3) Only one storage location at line for labels Purpose: Ensure no Part Mixing or wrong label applied at final pack-out. Step 3 Quality Inspection Level 3 3 QC does 200% check which includes label validation and records result in inspection log by serial number for each tote. See example below: 2) Inspection Manuals are posted at the line Purpose: Ensure no wrong label applied by production and packing process

Match 4 5 6 4 5 6 Supplier Label DENSO Label Page 16 of 25 5.4 Level 3 Warehouse Labeling Electronic Confirmation Level 1 Manufacturing Line Side Labeling Electronic Verification <Overall Level 3 Process> Manufacturing Process Warehouse Label Apply 4 5 6 Change Over or Start-up Production / Packing Inspection Management Layered Audit Apply Label Process Quality Inspection Apply DENSO Label Process Level 3 4 <Electronic Confirmation of Shipping Label Part Number> Purpose: Ensure Label on Box Match parts in container by electronic check. Use Scanner to Electronically confirm that the Internal Label and DENSO Shipping Label part number and quantity match. The scanner should also record label serial history for traceability from Manufacturing Date and Time to shipping label. Supplier Label GM12356 QTY = 4 DENSO Label Quality Inspection: Check 1 Piece Per Box Check Level 3 5 Check 1 part per container per DENSO Label to verify that the part matches DENSO Label. Note: Not required if manufacturing equipment electronically verifies parts to label Container Part Label = DN145 Part = DN145 Match DN145 DN145 Purpose: Confirm Parts matches DENSO label. Management Layered Audits Level 3 6 Key Point: Management must complete layered audits to ensure processes are being followed. (Example Leader Check Frequency (Line Leader – 2 times per week, Supervisor (1 time per week) , Plant Manager (1 time per month) Purpose: Ensure by several different levels of management that standardize processes are being followed and are working well for the associates

6.0 Level 4 Warehouse Labeling Manual Confirmation Page 17 of 25 6.0 Level 4 Warehouse Labeling Manual Confirmation Level 4 Warehouse Labeling Manual Confirmation

6.1 Level 4 Warehouse Labeling Manual Confirmation Page 18 of 25 6.1 Level 4 Warehouse Labeling Manual Confirmation Level 1 Manufacturing Line Side Labeling Electronic Verification Example <Manual Confirmation of Shipping Label Part Number> Confirm Supplier Kanban and DENSO part number and quantity match. After confirmation Apply DENSO Label to tote or box. Manually confirm that the Internal Label and DENSO Shipping Label part number and quantity match. The internal label should be saved for 3 months with the DENSO D.O. number for traceability. DENSO label Supplier Label TN12000G QTY = 4 <Manufacturing Labeling with Supplier Internal Tag> Item Requirements Change Over or Start-up Start up / Change Over / Rotation / Shift Change Verification *Changeover Check Sheet Key Items: First piece check includes label matches actual part, Validation of no old labels left at process, and only one part # at work cell. Production / Packing Production tracking log that tracks part number, lot number, production date, and time. Production manuals posted at station which includes label validation. 3) Only one storage location at line for labels Inspection QC does 200% check which includes label validation and records result in inspection log by serial number (each tote). Manuals are posted at the line Note: If Manufacturing equipment 100% electronically verifies parts match label by vision system or part ID scanning than 200% check is not required. <Warehouse DENSO Label Apply Process> Item Requirements Label Generation and Control Labeling Sign-Out Log. Once Shipping Labels are generated from NASWEB a Sign-Out Log is utilized which is controlled by management to track the label issuing to manufacturing line. Key Information on Sign-out Log. Part Number, # of Labels Issued, Ship Date, Associate that printed the labels, and Issue to line date. Label Process Confirm Supplier Kanban and DENSO part number and quantity match. After confirmation Apply DENSO Label to tote or box. Then complete 1 piece check to confirm correct label. Manually confirm that the Internal Label and DENSO Shipping Label part number and quantity match. The internal label should be saved for 3 months with the DENSO D.O. number for traceability. 1 Piece Check per Box 1 piece per DENSO Label is verified that part matches DENSO Kanban. Note: Not required if manufacturing equipment electronically verifies parts to label Management Layered Audits Key Point; Management must complete layered audits a minimum of one time per month to ensure processes are being followed.

1 1 Level 1 Manufacturing Line Side Labeling Electronic Verification Page 19 of 25 6.2 Level 4 Warehouse Labeling Manual Confirmation Level 1 Manufacturing Line Side Labeling Electronic Verification <Overall Level 4 Process> 1 Manufacturing Process Warehouse Label Apply Change Over or Start-up Production / Packing Inspection Quality Inspection Management Layered Audit Apply Label Process 1 Change Over or Startup Level 4 Changeover Check Sheet Key Items: Purpose: Ensure no Part Mixing occurs during changeover, rotation, and or Shift Change. Confirm label control is handled as part as changeover.

Page 20 of 25 6.3 Level 4 Warehouse Labeling Manual Confirmation Level 1 Manufacturing Line Side Labeling Electronic Verification <Overall Level 3 Process> Manufacturing Process Warehouse Label Apply 2 3 Change Over or Start-up Production / Packing Inspection Quality Inspection Management Layered Audit Apply Label Process Production and Packing Level 4 2 Production tracking log that tracks part number, lot number, production date, time, and Supplier Internal Identification. 2) Production manuals posted at station which includes label validation. 3) Only one storage location at line for labels Purpose: Ensure no Part Mixing or wrong label applied at final pack-out. Quality Inspection Level 4 3 QC does 200% check which includes label validation and records result in inspection log by serial number for each tote. See example below: 2) Inspection Manuals are posted at the line Purpose: Ensure no wrong label applied by production and packing process

Page 21 of 25 6.4 Level 4 Warehouse Labeling Manual Confirmation Level 1 Manufacturing Line Side Labeling Electronic Verification <Overall Level 3 Process> Manufacturing Process Warehouse Label Apply 4 5 6 Change Over or Start-up Production / Packing Inspection Management Layered Audit Apply Label Process Quality Inspection Apply DENSO Label Process Level 4 4 <Manually Confirm Shipping Label Part Number matches Internal Tag> Purpose: Ensure Label on Box Match parts in container. Manually confirm that the Internal Label and DENSO Shipping Label part number and quantity match. Manually record the label serial history for traceability from Manufacturing Date and Time to shipping label. DENSO label Supplier Label TN12000G QTY = 4 Quality Inspection: Check 1 Piece Per Box Check Level 4 5 Check 1 part per container per DENSO Label to verify that the part matches DENSO Label. Note: Not required if manufacturing equipment electronically verifies parts to label Container Part Label = DN145 Part = DN145 Match DN145 DN145 Purpose: Confirm Parts matches DENSO label. Management Layered Audits Level 4 6 Key Point: Management must complete layered audits to ensure processes are being followed. (Example Leader Check Frequency (Line Leader – 2 times per week, Supervisor (1 time per month) , Plant Manager (Quarterly) Purpose: Ensure by several different levels of management that standardize processes are being followed and are working well for the associates

7.0 Repack Control in Warehouse Page 22 of 25 7.0 Repack Control in Warehouse Repack in Warehouse

7.1 Repack Minimum Standards Page 23 of 25 7.1 Repack Minimum Standards Repack: Repack Finished Goods from supplier or in-house production to same or different lot size and placing new Label on parts prior to shipping to DENSO. Below is list of minimum requirements to prevent wrong DENSO Shipping label applied.

8.0 Supplier Label Requirements & QR Code Spec Page 24 of 25 8.0 Supplier Label Requirements & QR Code Spec <DENSO Container Label Specification> Due Date Block Title = Due Date Data = Delivery due date Text Height = 6 mm Source = 862 Segment DTM02(002) Maximum Length = 8 Part Number Block Title = Part Number Data Identifier = P Data = Part Number (including dash) Text Height = 7 mm Source = 862 Segment LIN03(BP) Maximum Length = 15 Plant Code Block Title = Plant Code Data = Ship to plant Text Height =14 mm Source = 862 Segment N104(ST) Maximum Length = 2 Location Block Title = Location Data = Warehouse location Text Height = 6 mm Source = 862 Segment REF02(RL) Maximum Length = 5 Description Block Title = Description Data = Part Description Text Height = 5 mm Source = 862 Segment LIN05(PD) Maximum Length = 30 Block Title = Qty Data Identifier = Q Data = Based on Order quantity and Box quantity Text Height = 7 mm Source = 862 Segment P0402(BX) Maximum Length = 8 Serial Number (by supplier code) Block Title = Serial # Data Identifier = 3S Data = Based on Supplier code and serial number (including dash) Text Height = 7 mm Source = 862 Segment N104(SU) Maximum Length = 12 Control Number Block Title = Control # Data = Control number from 862 Text Height = 6 mm Source = 862 Segment LIN07(KP) Maximum Length = 4 Warehouse Block Title = Warehouse Data = Receiving Warehouse Text Height = 6 mm Source = 862 Segment REF02(RV) Maximum Length = 1 Label Purpose: Identifies a part number in the container Size: 4 x 6.5; cardstock. Illustration is NOT actual size. Any dimensions that are not otherwise specified on this page SHALL be in compliance with AIAG B-10.

<Label Supplier Information> Page 25 of 25 8.1 Label Specification <Label Supplier Information> Label Requirements: Labels need to be printed on 6.5 in x 4 in kanban stock (Not Paper). (Specs below). You can select your own supplier for the stock if you have another supplier, but it must be card stock (Printing on paper not acceptable.