2. Problem:
o Improper arrangement of packed parts.
o Parts have direct contact resulting in
damages (such as scratches, dents).
Solution:
o Vertical or horizontal separators should be
used to avoid damage to the parts.
o Layers should be installed for proper
weight distribution.
3. Problem:
o Poor quality of boxes provided by
suppliers and same was carry
forwarded in CKD.
o No 100% quality check.
Solution:
o Standard boxes must be used instead
of the ones provided by the suppliers
as they are not sturdy & export
worthy.
o 100% visual Quality inspection of the
parts must be done before inserting it
in the box.
4. Problem:
o Boxes are overloaded beyond their
maximum capacity to accommodate
more parts
o Bending/ bulging at the edges , may
resulting to case collapsing in transit..
Solution:
o Boxes must not be overloaded as its
overall strength reduces and may
result in tearing of the box which is
detrimental to the parts inside.
o Some sort of support at the edges and
the corners can be given to avoid such
a situation
5. Problem:
o Supplier Polythene bags has been
carry forwarded in CKD packing
resulting in tear & part scratches and
damages.
Solution:
o Suppliers packing should not get carry
forwarded . VCI bags / Bubble bag
must be used for metallic parts to
damages and subsequent resulting
into rusting.
6. Problem:
o No care is taken for fragile parts.
Solution:
o Separate compartments should be
provided for fragile parts like indicator
lamps, head lamps etc to avoid
damages.
o It is to be ensured that no heavy parts
should be kept over such fragile
components.
7. Problem:
o No quality inspection is done after
receiving the material from the
supplier and is directly packed.
Solution:
o Quality inspection for all the parts
must be done thoroughly before
packing.
11. Separators were not used
Separators were added
and parts were
arranged properly
12. BEFORE
No separators were used, which
caused the DDU & air tanks to move
during transportation resulting in
damage
AFTER
Separators were used which resulted
in compact packing
13. BEFORE
Assy. Mounting strap kept haphazardly
and on top of each other
AFTER
Assy. Mounting strap arranged neatly
with separators
14. BEFORE
Brackets were kept together sometimes
with DDU which may result in damage
AFTER
Brackets were given separate
compartments to avoid contact with
other parts
15. BEFORE
Wiper arms are kept in single
compartment with wiring harness
resulting in damage
AFTER
Wiper arms separated by separators
and arranged properly
16. BEFORE
All wiring harness kept improperly
AFTER
Separate layer is provided for proper
arrangement of wires
17. Packing of fuel tank
Separate box is provided for each fuel tank
18. Packing of leaf springs
8 Springs are placed in one layer. Both the layers are separated by wooden bars & Steel pallet / ESR
suggested in place of wooden box.
