Packaging design and precautions for auto parts export
The export
of auto parts is the export of automobile KD parts, and automobile KD packaging
design is a systematic project.
1-Packaging of KD export pats:
To
design the packaging of KD export parts for a car model, many factors need to
be considered, such as automobile manufacturing process tempo, logistics links,
packaging materials, customs requirements, etc. The design process needs to
consider quality, cost, handling operations, assembly technology, and
identification.
KD assembly:
KD assembly form provided to foreign suppliers
mainly includes three forms:
·
SKD1,
·
SKD2
and
·
CKD.
SKD (Semi-Knocked Down)
SKD assembly form refers to
"semi-bulk". In the export state of the spare parts, the body is
supplied in the form of a welded and painted assembly, and other parts such as
the engine, transmission, front/rear suspension, drive shaft, exhaust system,
wheel assembly and front/ the rear bumper, etc. are supplied in the form of an
assembly. After the spare parts are shipped abroad, they are only simply
assembled to complete the vehicle.
SKD1:
SKD1 means that the car body is painted, and
the seats, interior parts, front/rear windshields, door glass, car lights and
other exterior parts are installed.
SKD2:
SKD2 means
that the car body is only painted (or only electrophoresis), without any
interior and exterior trim parts.
CKD (Completely Knocked Down):
CKD assembly
form means "completely disassembled". In the state of export of
bulk parts, the body is supplied in the form of dispersed welded assembly, and
other parts are supplied in the form of assembly. After going abroad, welding,
painting and final assembly processes are required to complete the vehicle
assembly.
2 Packaging design input
conditions:
I.
complete
assembly BOM
II.
A complete assembly BOM is the basis for the
design work. The BOM for KD export parts should include part codes, Chinese and
English names, bicycle usage, net weight, and main parts. Material and other
information.
III.
The compilation of assembly BOM
should consider the following points.
a. Confirm the KD status with foreign
investors before compilation.
b. b. The foreign business shall
check whether it meets the requirements of the customs of the importing country
(the tariffs on parts and components of different product names are very
different).
c. c. The BOM file is a process
file used by overseas factories for warehousing and assembling parts and
components, which should be maintained and updated.
(3) Packaging requirements of
importing countries:
a. Recyclability and environmental
protection requirements of packaging materials.
b. b. Special requirements
for packaging materials, such as whether the wood needs to be baked or
fumigated.
(4) Packaging design principles
When designing packaging, you need to master
certain design principles, mainly from the aspects of protection, cost, and
ease of loading and unloading.
a. Parts protection: simple operation,
reliable, moisture-proof, rust-proof and scratch-proof.
b. Packaging cost: use local materials that are
easy to buy and cheap.
c. Container loading and unloading: the container
loading and unloading operation is convenient, easy to fix, and the quality
distribution is reasonable.
d. Automobile assembly process: according to the
assembly process, the parts are packaged and grouped, that is, the parts of
similar processes are packed together.
e. Marking requirements: accurate, practical and eye-catching
information to be transmitted.
f.
The container utilization rate is as high as
possible: generally ≥90%. 4 Packaging design process
(5)Determine the economic shipping batch with foreign businessmen:
To determine how many sets are shipped in each
batch. Generally, the economic batch is 24, 30, 60, 120, etc., which can meet
the packing combination of different quantities of parts to the greatest
extent. Once the economic batch is determined, subsequent orders must be
ordered in an integer multiple of the economic batch, and the packaging unit
and packing box are also designed according to the economic batch.
(6) Recognition and classification of
parts by packaging engineers.
The shape, size, quality and characteristics
of automobile KD parts can be described as vastly different, and the general
classification is as follows.
a.
Fragile parts: windshield and door glass, sunroof, rearview mirror, etc.
b. Easily
scratched parts: door trim, headlights, instrument panels, etc.
c.
Chassis parts: frame, front/rear suspension, drive shaft, axle, exhaust system,
etc.
d.
Interior decoration parts: ceiling, seat, carpet, sealing strip, etc.
e.
Easily corroded parts: body sheet metal parts, brake discs, axles, etc.
f .High-value
parts: engine, transmission, CD player, ECU, hydraulic control unit, etc.
Purpose of classification:
The
purpose of classification is to design packaging boxes more specifically.
Use
air cushion film bags or sponge strips for auxiliary support for fragile parts;
use high-strength corrugated cartons to
package interior parts to prevent them from being crushed; spray anti-rust oil
and use anti-rust film protection for easily rusty parts;
High value the design strength of the parts
packaging can be moderately excessive to prevent excessive losses after an
accident.
(7) Design transport packaging unit:
Before
designing the packaging, we must first understand the size of
the container (special container). General containers are divided into
20-foot container, 40-foot general container, 40-foot high container and
special container. The specific dimensions are as follows: a.20-foot container:
The content volume is 5690mm×2340 mm×2180 mm, the gross weight of the
distribution is generally 17.5 t. b. 40-foot general-purpose
cabinet: the internal volume is 11800mm×2340mm×2180 mm, and the gross weight of
the distribution is generally 22 t. c. 40-foot high cabinet: The internal
volume is 11800mm×2340mm×2680 mm, and the gross weight of the distribution is
generally 22 t. At this stage, 40-foot tall containers are generally used.
When designing packaging, the width of the packaging unit is generally no more
than 2280mm, and the height is generally no more than 2560mm (this height is
the height of the packaging unit after stacking), and the container mouth
should generally be left with 120 The distance of ~200 mm (this distance
depends on the packaging unit) in order to avoid the cumulative error of the
packaging unit size and the smooth packing. The transport packaging unit
refers to a packaging unit that is easy to transport and is composed
of several turnover boxes, metal pallets, racks, storage cages and
other parts. It is also a primary packaging unit packed into a
container. The packaging engineer should first design the packaging unit
for large or special-shaped parts according to the appearance characteristics
of the parts, such as the frame, side panels, engine, front/rear bumpers,
exhaust pipes, etc., which are called bulk packaging units. The packaging
unit of these parts is generally designed according to the size of the parts in
the length and height direction, and the width direction (after the parts are
arranged) is designed according to the standard size, such as 2280mm or 1140mm,
so that the width of 2340mm is just used, and the packaging is proposed.
Characteristics of the unit:
The
characteristics of the unit, such as size, quality, whether it can be stacked,
etc. When designing large packaging units, computer-aided design is used
for spatial layout, which can be very fast and accurate for physical simulation
arrangement to improve space utilization, as shown in the figure below.
After the
design of the large packaging unit is completed, a dedicated boxing engineer
will arrange the containers
(8) Fill in packaging unit:
After
determining the vacant size, design a packaging unit specially used to fill the
vacant area according to the characteristics of the parts. The packaging of
plastic parts, exhaust pipes and tires is called a fill-in packaging unit.
The other
smaller parts are designed according to the standard size of the packaging
unit, called the standard packaging unit, the size is generally 1140mm (or 2280
mm) × 1480 mm × height, the height is determined according to actual
needs. After the design size of the standard packaging unit is determined,
the corresponding packaging box size can be determined accordingly to
facilitate the completion of the packaging.
(10) Formulating process cards
and process documents:
After the packaging design is completed, the quota of
packaging materials, packaging process cards, as well as the loading and
unloading process documents used to guide the actual production, procurement
and logistics should be formulated.
(11) Selection and analysis of
packaging materials and structures:
Packaging
materials can be roughly divided into six types: paper products, foam materials, plastic/rubber products, wood
materials, metal materials and mineral desiccants.
Board,
honeycomb cardboard, paper corners, ordinary corrugated boxes, heavy corrugated
boxes and honeycomb boxes
The commonly used
carton box types are as follows.
a. Slotted type.
Usually composed of a piece of corrugated
cardboard, the top and bottom flaps form the bottom and the lid of the box, and
the carton is made by nailing or gluing.
b. Fitting type.
The carton consisting of several pieces of
blanks is characterized by the separation of the bottom, cover and other
parts. When in use, the cover, bottom and other parts of the box are
combined to form a carton.
c. Box cover type.
A box made of honeycomb
cardboard with L-shaped paper corners classified by packing purpose as follows.
a. Ordinary corrugated
boxes
. It is mainly used for the assembly of bulk parts. According to the
characteristics and dimensions of the parts, determine the placement method in
the carton, and then select appropriate protective materials for
protection.
b. Heavy-duty
corrugated boxes.
Heavy-duty carton packaging is used for large-volume interior and
exterior trim parts and chassis parts with a relatively large quality, which
can play a good load-bearing role, and will not damage the components due to
carton material problems when stacking.
(12) Foam material:
Foam material mainly plays a buffering role,
mainly including air cushion film, pearl cotton, pearl cotton bag, pearl block,
sponge protection strip, foam, foam, high-pressure polyethylene.
·
Plastic/rubber materials Plastic/rubber materials mainly
include plastic films, air cushion films and bags, anti-rust film bags, plastic
bags, plastic hoses, rubber sheets, protective films, paint protective films,
plastic hollow boards, packing belts, etc.
·
Wooden materials. As log packaging needs to be fumigated
for export, most companies now use fumigation-free plywood pallets, plywood and
compressed wood. Examples of pallets are as follows. Plywood pallets are
divided into two-way and four-way fork pallets for single-sided use, type I and
type II. The top plank of the pallet can be selected from 1 plywood or
multiple plywood according to the load-bearing situation; the thickness of the
top plank and the bottom plank should be selected according to the quality of
the loaded goods; the number of stringers is determined according to the pallet
size.
The
total height of the company's existing plywood pallets is generally 100 mm.
(13) Metal materials:
Metal
materials mainly include profiles, plates, cushioning materials, standard parts
and fasteners. Metal pallets, metal turnover boxes, turnover racks,
storage cages, and wire edge appliances are common metal tooling appliances in
automobile. At present, metal tooling is mostly a combined tooling, that
is, a tooling composed of a bottom frame, an end frame, and a side frame with
standard parts. This tooling design can effectively save production space,
and the steel specifications are smaller, which can reduce costs. While
promoting standardized production, three-dimensional stacking can be easily
realized through standard couplings. Metal tooling is mainly used for the
packaging of sheet metal parts and high-quality parts, such as engines,
transmissions, axles, front/rear wind windows and door glass.
For more details please visit:http://www.biotechpackages.com/
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