REQUIREMENTS

MANUAL
Global Packaging and Shipping Standards
for Suppliers
Revised: Jan 2018

Goals:
1. All parts received to the point of use with superior quality
2. Packaging complies with Delphi Technologies Standard Container and
Pallet Menu options
3. Parts presented with operator ergonomics and work cell efficiencies
considered
4. Achieve 90% container density and maximize the cubic shipping
footprint while minimizing costs
5. Provide for responsible disposal of used packaging by designing in
recyclable materials and minimizing disposal impacts to the
environment
 Delphi Technologies Global Packaging and Shipping Requirements Manual

Requirements Manual
G L O B A L PAC K A G I N G A N D S H I P P I N G S TA N DA R D S F O R S U P P L I E R S

I. TABLE OF CONTENTS
Section Topic Page #
I Table of Contents 1
II Introduction 2
III Responsibilities 2
A Delphi Technologies Responsibilities 2
B Supplier Responsibilities 2
IV Quick-Start Menu 3
V Quoting / Pricing 4
VI Packaging Systems Requirements 5
A Container Design 5
B Returnable Container / Packaging Materials 6
C Expendable Container / Packaging Materials 7
D Dunnage and Additional Considerations 7
E Ergonomics and Performance (Height and Weight) 7-8
F Factors 8
G Pallet Design and Construction 9
H Special Packaging Systems 10
I Testing and Validation 10
VII Dangerous Goods / Hazardous Materials 11
VIII Shipping Standards 11
A Container Labeling 11
B Transport / Paperwork 12
C Palletization / Unitization 12
D Securement Materials 13
IX Supplier Portal 14
X Change Management 14
XI Check Yourself 15
XII Standard Container and Pallet Menu 16 – 18
XIII Glossary 19 – 20
XIV Revision History 21

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II. INTRODUCTION
This Delphi Technologies (known throughout this manual as ‘Delphi’) Global Packaging and Shipping Requirements
Manual specifies the packaging and shipping standards for materials being shipped to Delphi. The requirements in
this manual apply to all current and future parts being shipped to Delphi. Note: This revision supersedes all
previously published guidelines, requirements, or standards by Delphi or its Divisions.
Delphi is concerned with safe movement of material, part quality, control of total costs, and compliance to
regulations. Each Supplier (both internal and external) shall develop its production packaging to meet the basic
requirements contained herein and to ensure part quality from their facility to the point of use. If Delphi
requirements are not met or part quality is compromised, the Supplier will be held responsible for costs related to
packaging redesign, repack, inspection, and freight.

III. RESPONSIBILITIES
A. Delphi Technologies Responsibilities
1. Define the preferred packaging system (expendable and/or returnable).
2. Assist the Supplier with its packaging plan, as required.
3. Approve the Supplier’s packaging plan.
4. Determine system size, quantity, allocation, and management of returnable containers.
5. Monitor and assure compliance to Delphi requirements.

B. Supplier Responsibilities
1. Comply with the current Delphi Packaging and Shipping Requirements Manual and Customer
Specific Requirements.
2. Design the pack (container design, container dunnage, closure, etc.) and packaging system
(unit-load design, overpack, palletization, securement, etc.) to ensure part quality from origin to
destination point of use (during transport, handling, and storage).
3. Discuss any questions with the Delphi Packaging Responsible Person (PRP) to ensure all
requirements are clearly understood and met. Contact Delphi Buyer if the PRP name is not known.
4. Submit all required packaging documentation with part quote submission(s).
5. Ensure that the packaging design and materials meet governmental, industry, and transport
modal requirements; provide results to Delphi upon request.
6. Ensure that the packaging design and material is validated by an accredited laboratory
prior to program start-up dates; provide results to Delphi upon request.
7. Provide sample production intent packaging and back-up packaging with parts.
8. Obtain formal approval (Supplier Packaging Information Form) from the Delphi PRP for
Supplier-designed packaging before shipments commence and provide with PPAP submission.
9. Ship all production intent parts in production intent packaging.
10. Ensure that sufficient materials and contingency plans exist to protect continuity of supply.
11. Annually review packaging for compliance to Delphi’s current requirements and resubmit for
approval when requested by Delphi, or when:
a) There is a Quality occurrence,
b) There is a Change; e.g., part design, packaging design, volumes, standard pack
quantities, transport mode, ship-to location, regulatory requirements, etc.
NOTE: Non-compliance will result in a Problem Case and Cost Recovery (PC/CR).

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IV. QUICK-START MENU

Select packaging container and pallet from Delphi’s

1 Standard Container and Pallet Menu

Submit packaging plan to Delphi Technologies (via RFQ

2 process or change process)

Obtain packaging approval from the Delphi

3 Technologies Packaging Responsible Person (PRP)

Place manufactured goods for Delphi Technologies in

4 approved container and affix container labels

Palletize containers (flat layers), secure the load, and

5 attach required paperwork (packing slip, etc.)

Deliver goods and shipping documentation to carrier or

6 freight forwarder for transport

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V. QUOTING / PRICING
Packaging costs shall be included with all part quote submissions and clearly itemized in the piece price. When
responding to a Delphi Technologies Request for Quotation (RFQ), Supplier shall quote all packaging as
expendable. All packaging pricing is negotiated with Delphi Supply Chain Management Commercial (Purchasing
Buyer). No price increases will be granted to correct defective and/or non-conforming packaging.
If an opportunity to utilize returnable packaging exists, the Supplier and/or the Delphi PRP shall investigate the
feasibility of this option and present the returnable proposal. Delphi will not pay for additional packaging to
support Supplier’s buffers. Handling, storage, cleaning, and return of returnable packaging terms shall be
approved by the Delphi Buyer and Delphi PRP.

Tech
review

If a specific container requirement has not been included in Delphi’s RFQ, use the Packaging Workflow for Container
Selection (below) to select a right-sized container from Delphi’s Standard Container and Pallet Menu. All containers
shipped to Delphi facilities shall be chosen from the Delphi Standard Container and Pallet Menu unless product
dimensions necessitate a non-standard container and formal approval has been obtained in writing from the Delphi
PRP.
NOTE: Packaging changes resulting from part design, packaging materials, and/or standard pack quantities during
the quote stage require resubmittal to Delphi. Changes after business award shall follow Change Management (see
Section X).

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VI. PACKAGING SYSTEMS REQUIREMENTS

Packaging design shall be aligned with standard dimensions as specified within this manual. The Supplier is
responsible to work with its packaging vendor(s) to ensure that the defined packaging is compliant to Delphi’s
requirements and ergonomic standards.
The package design and Standard Pack Quantity (SPQ) for the same part number shall not vary unless otherwise
approved in writing by the Delphi PRP.
Only one (1) component part number is allowed per individual container unless otherwise approved in writing by the
Delphi PRP (special circumstance examples: complimentary ‘mating’ part numbers, kitting, etc.).
The ‘Packaging System’ is the cooperative grouping of the individual container design (either returnable container
with back-up expendable or expendable container), dunnage, palletization, and securement materials. The unit-
load design shall consider both standard and expedited modes of transport. Under no circumstances shall dirty or
damaged packaging materials be used for shipments to Delphi facilities.

A. Container Design
All container designs shall be stackable and rigid with no excessive flexing, bowing, buckling or distortion.
Sharp or protruding edges/ridges are prohibited.
If handholds are required, select the appropriate type of handhold for the container; e.g., hinged access
holes for expendable containers, D-shaped or molded handles for returnable containers, accommodate
gloved hands, and position handholds above the center of gravity.

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B. Returnable Container / Packaging Materials

A returnable container system is designed for multiple years of functional use. The design and selection of
the returnable container shall meet all Delphi requirements. Expendable back-up packaging for the
returnable production container shall be equivalent in size to match the footprint, part quantity, part density,
and part presentation. The Delphi PRP shall provide approval for the returnable system proposal, including
back-up packaging, dunnage, and system size (loop size).

• All returnable containers shall include a card holder and/or label placard.
• Containers shall include ‘Made in (Country)’ markings and a unique identifier; e.g., the container part
number.
• The tare weight shall be stamped into the individual components of the returnable container system.
• Resin Identification Code(s) for all vacuum-formed and injection-molded plastic packaging materials
shall be stamped into the individual components of the returnable container system.

Returnable containers may be owned by Delphi or the Supplier; ownership shall be determined during
sourcing. Returnable container rental and collapsible returnable containers may also be pursued as options.
Delphi-owned returnable containers are to be used only for finished goods shipments of Delphi products.
Containers and returnable dunnage are to be maintained in good order.
Returnable Container Management:
Party # Responsibility
Delphi 1. Maintain, repair, supplement, and dispose of Delphi-owned systems
Assure empty containers are free of debris and expendable packaging materials
2.
prior to shipment of empty containers to Supplier
3. Coordinate any economic feasibility study for acceptable return on investment
Supplier 1. Maintain, repair, supplement, and dispose of Supplier-owned systems
Regularly inspect and clean containers to ensure part quality and cleanliness
2. (regardless of ownership); remove all one-time shipment labels and expendable
dunnage
Load production parts into clean undamaged containers and load container systems
3.
into transport equipment in a manner that maintains part quality
Assure accurate container identification and quantities (including pallets, returnable
4.
dunnage and containers) are included in the Advance Shipping Notice (ASN)
Maintain receiving and shipping records of all Delphi-owned returnable packaging
5. (including outbound shipments by container and location, Supplier in-house reserve,
and balance not returned from each Delphi location)
Alert/contact the Delphi receiving plant’s Production Control Department when/if
6.
shortages begin to occur

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C. Expendable Container / Packaging Materials

Regular Slotted Containers (RSC) and Half Slotted Containers (HSC) may be used as defined in the
Standard Container and Pallet Menu. When HSCs are used, individual lids or full-layer covers are
acceptable (confirm with PRP for preference); uncovered (uncapped) HSCs are not permitted.
RSC HSC Drop Side Bulk

Corrugated materials shall have sufficient strength (minimum 44 ECT) to maintain part quality during
transport and in storage. All containers shall have a Box Manufacturer’s Certificate (BMC) stamp visible on
the assembled container displaying the edge crush (ECT) or burst(ing) strength, construction type (single,
double, or triple wall), and maximum allowable weight. Flute direction shall be vertical to optimize the
compression strength of the container. All containers shall be constructed with an outside tab-style
manufacturer’s joint. A stitched manufacturer’s joint may be required if a glued or other type joint proves
inadequate.
The use of scored drop sides on palletized/bulk containers may be required. The location and size of the
drop side is determined by part orientation and operator ergonomics. Consult the Delphi PRP for further
clarification.
Expendable packaging shall be adequately sealed to ensure failure does not occur during shipping,
handling, or distribution. The required closures for corrugated boxes are glue and/or packing tape; staples
and asphalt sealing tapes are forbidden.

D. Dunnage and Additional Considerations

Dunnage is considered to be any packaging component that requires a container or a pallet to be
shippable; e.g., vacuum formed trays, corrugated partitions, layer pads, etc. Dunnage shall be used to
prevent damage in container loading/unloading, shipping, handling, or for special case situations; e.g., part
cleanliness, moisture protection, corrosion protection, Electrostatic Discharge (ESD) protection, surface finish,
part movement restrictions, etc.
Suppliers are responsible for the design, performance, and procurement of all dunnage. Container loading,
unloading, recycling, and disposal shall be considered during the design phase. The use of non-recyclable
materials is prohibited unless approved by the Delphi PRP.
Parts plus dunnage shall fill the container to prevent compression failures due to void space. Part orientation
within the container shall match the part orientation used by the operator, allow space to accommodate
fingers/hands, and minimize forces required for part placement/removal. Pallet-sized ‘corrugated sheets’
(a.k.a. pads) are permitted for use on the bottom layer and between layers.

E. Ergonomics and Performance (Height and Weight)

The maximum acceptable weight of a container depends upon container specifics, weight of goods being
packaged, and human factors. At a minimum, Supplier shall use the National Institute for Occupational

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Safety and Health (NIOSH) Lifting Equation as the basis for its weight limit analysis. If the selected
container exceeds its weight limit, Delphi may require the Supplier to modify the design and/or perform
additional ergonomic analysis prior to issuing approval.
Pallet loads shall be designed for safe stacking during transport and in storage. The unit-load construction
requirements are listed in the table below and align with transport routing requirements. Supplier shall
respect all regulations for the value stream (countries of origin, transit, and destination).

# Required Design Elements Metric System Imperial System

Height of an individual unit-load shall not exceed:
Standard ocean container 1168 mm (1.168 m) 46 inches (3’10”)
1. Standard truck or high-cube ocean container 1320 mm (1.320 m) 52 inches (4’4”)
Mega truck For 3 unit-loads: 965 mm (0.965 m) 38 inches (3’2”)
For 2 unit-loads: 1450 mm (1.450 m) 57 inches (4’9”)
Dynamic Stack Height (during Transport) shall not exceed:
Standard ocean container 2336 mm (2.236 m) 92 inches (7’8”)
2.
Standard truck or high-cube ocean container 2640 mm (2.64 m) 104 inches (8’8”)
Mega truck (typically 3 unit-loads) 2900 mm (2.9 m) 114 inches (9’6”)
Static Stack Height (during Storage) shall not exceed
3. 3200 mm (3.2 m) 126 inches (10’6”)
three (3) unit-loads or:
Maximum gross Weight of a manually-handled
4. 15 kg 33 lbs.
container:
5. Maximum gross Weight of a unit-load: 908 kg 2000 lbs.

A Delphi Technologies plant and/or Delphi’s logistics providers may require special labels on goods that
exceed 500 kilograms (1102 pounds) to alert material handlers to weight risks or on items requiring
handling caution; examples below.
‘Do Not Stack’ labels and ‘No Stack’ pyramids are strictly prohibited. The use of a ‘Do Not Stack’ label or
pyramid will not exempt the Supplier from over, short, or damaged product claims and will result in a
PC/CR.
ALLOWED: PROHIBITED:

F. Factors
Container density percentage for parts packaged in trays/dividers is analyzed by Delphi based on the
cubic dimensions of the container and standard pack. Delphi measures bulk pack density percentage
according to the formula below; target is 90%.

Height of goods in container

% Density (Bulk Pack) =
Height of container

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G. Pallet Design and Construction

The pallet shall have the minimum strength to withstand static and dynamic forces in the distribution
environment. Pallet design criteria shall be sufficient to prevent pallet deformations, damages, and
structural failures that may detrimentally affect the functionality of the unit-load. All unit-load shipments shall
be prepared on a wooden or plastic pallet. Acceptable pallet dimensions are listed in the Delphi Standard
Container and Pallet Menu; non-standard pallets require written approval by the Delphi PRP.
At a minimum, Supplier shall use the current ASTM D1185 Standard Test Methods for Pallets and Related
Structures Employed in Materials Handling and Shipping when designing its packaging system. This standard
is used by Delphi as the guideline for testing details and pallet acceptance criteria.

# Required Design Elements Metric System Imperial System

1. Non-reversible four-way entry stringer or block construction
2. Minimum load-bearing capacity shall meet unit-load and stacking requirements
3. Minimum primary opening height: 88 mm 3.5 inches (3½”)
4. Minimum secondary entry (4-way entry notch) height: 50 mm 2.0 inches (2”)
Nailed construction using four-flute helical hardened nails with a
5. 57 mm 2.25 inches (2¼”)
minimum length of:
6. Nail heads and points are to be flush, but may not exceed: 3 mm 0.125 inches (⅛”)
7. No missing boards or tapered breaks longer than: 254 mm 10 inches
8. No exposed splinters greater than: 76 mm 3 inches
9. No double stringers, patched boards, metal plates, winged pallets, or deck nails with shanks exposed.
10. No corrugated pallets, pressed wood pallets, chipboard pallets, or ‘slip sheets’
11. Pallets shall be clean and odor free; aging discoloration is acceptable.

All solid wood packaging materials shall be fully compliant to ISPM 15 (International Standards for
Phytosanitary Measures #15) and contain the required stamp. Non-ISPM15 solid wood materials are
prohibited and may not be used for materials delivered to Delphi.

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H. Special Packaging Systems

Special packaging systems may be utilized for different types of materials and industry packaging
standards (not limited by the examples list below). Review by the Delphi Technologies PRP is necessary
prior to shipment to Delphi.
At times, Delphi may choose to assume responsibility for the Packaging System when there are specialized
design requirements; e.g., a tray that is used by the Supplier for coating parts and then the same tray is
used by a robot at Delphi’s facility.

1. Wire Spools and Wire Fiber Drums (Barrels): Wire spools shall support the full weight
of the material during transport and handling. Spools and Drums (Barrels) may not overlap or
overhang in any dimension. Spools and Drums (Barrels) shall be secured to pallet with strapping (for
vertical orientation, use a 4-way pattern; for horizontal orientation, the strapping shall pass through
the core (arbor hole) of the spool).

Vertical Horizontal
orientation: orientation:

2. Convoluted Tubing: Bulk convoluted tubing may be packed in octabins; container(s) shall
be secured to pallet with two (2) lengthwise straps plus two (2) widthwise straps.
3. Terminal Reel Containers: Containers may not overhang the pallet in any dimension.
Pallet dimensions shall be optimized and assure stackability. A single terminal reel shipment without
a reel container is prohibited.
4. Surface Mount Component Packaging: Component Engineering maintains detailed
specifications (‘C-Specs’) defining additional requirements for device identification, labeling,
marking, and packaging.

I. Testing and Validation

The objective of packaging testing and validation is to ensure product protection. The Supplier shall ensure
part integrity and performance of the pack from origin to destination point of use (during transport,
handling, and storage). Approval by Delphi Technologies of the packaging system does not relieve the
Supplier of its responsibility for part integrity.
The Supplier is required to test the pack design under simulated and/or real conditions in a certified
packaging test laboratory. Packaging shall pass the current ASTM D4169 Standard Practice for
Performance Testing of Shipping Containers and Systems at the appropriate test level based on logistics;
testing elements include conditioning, vibration, and handling (drop and impact). Supplier’s validation results
and testing documentation are to be provided to Delphi in accordance with APQP (Advanced Product
Quality Planning). Delphi reserves the right to require additional testing and corrective action(s) at the
Supplier’s expense if part integrity is compromised and/or non-conforming packaging is discovered.

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# Required Design Elements Metric System Imperial System

1. Low Temperature*: -29 ± 2°C -20 ± 4 °F
2. High Temperature*: 60 ± 2 °C 140 ± 4 °F
3. Vibration, Drop, and Impact Tests based on routed freight mode
4. Compression Test considering the Static and Dynamic Stack heights (see Section VI. E.)
5. Additional tests as required by Delphi’s Product Engineer or Packaging Responsible Person
* May vary based on Origin and Destination

NOTE: Delphi has a certified Packaging Test Lab in its Mexico Technical Center (Juarez, Mexico). It contains
specialized equipment to test material and packaging in various transportation and handling conditions
(vibration, compression, drop, impact, and environmental).

VII. DANGEROUS GOODS / HAZARDOUS MATERIALS

A Supplier offering Dangerous Goods (DG) / Hazardous Materials (HazMat) for transport is responsible to
properly classify, package, mark, label, placard, document, and ship the material. Supplier shall be in compliance
with all DG/HazMat regulations and requirements (international, federal, state, provincial, and local) governing the
countries of origin, transit, and destination.
The packaging design and testing for DG/HazMat shall be aligned with the specific transport mode and expedited
mode(s) that will be utilized in production. DG/HazMat packaging shall comply with the United Nations (UN)
packaging symbol requirements and have a valid test report and certification date. If a packaging variation has
been granted by a competent authority, copies of all exemption and exception documentation shall be supplied to
the Delphi PRP and Buyer.
Supplier is required to provide a current Safety Data Sheet (SDS) to Delphi Technologies Environmental Engineering
(and/or the destination’s Hazardous Material Committee) for all materials. The transporter/carrier for all
DG/HazMat shall be provided a copy of the SDS and/or an emergency response guide.

VIII. SHIPPING STANDARDS

The Packaging System is subject to humidity, pressure, and temperature extremes during transport. Adequately
designed packaging will consider the standard mode(s) and expedited mode(s) of transport. Goods shipped via air
freight, parcel, less-than-truckload (LTL), or expedited modes require reinforced packaging due to additional
handling and rough treatment; e.g., higher carton ECT, dunnage, stronger/additional tape, etc.
Supplier shipment preparation shall ensure that the load is durable, stackable, secure, and compliant to regulations
(governmental, international, federal, country, state, provincial, and local). Supplier shall include proper labeling
and documentation with all products shipped.

A. Container Labeling
Goods delivered to Delphi are to be correctly labeled according to Delphi’s Global Container Label
Requirements Standard found on www.delphi.com in the Delphi Supplier Standards documents section. All
packaging shall be identified with required Delphi compliant container label formats containing accurate
alphanumeric characters, legible print, and electronically scannable barcodes. If placards are available on
returnable containers, utilize this area to apply shipping labels.

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Labeling deviations may only be approved by using the PC&L Supply Chain Requirements Deviation Form
(HOGW_4-2_SC-DIR_37-01_EN); signatures of the Buyer, Global Category Team Manager, and Divisional
Production Control Director are required.

B. Transpor t / Paperwork
When Delphi is responsible for transport costs, Supplier shall deliver the goods to Delphi’s specified carrier
or freight forwarder (based on contracted Incoterms). Suppliers shall make dock door available for
scheduled/established carrier window times and allow Driver dock access to verify/supervise loading of
material. Supplier shall accommodate Driver directions; e.g., loading and stacking material in the trailer,
unloading/reloading another Supplier’s empty containers, rearranging pallets to maximize trailer utilization,
etc.
Supplier shall follow additional requirements as issued by Delphi’s Logistics Department.
It is the Supplier’s responsibility to ensure that required paperwork (labels, packing slip, bill of lading,
dangerous goods paperwork, etc.) accompanies the goods at time of shipment.
When a Supplier ships direct to Delphi’s Customer; e.g., contracted arrangement, drop-ship, direct-ship,
expedite, diversion, etc., it shall comply with the requirements of Delphi and its Customer (including transport
mode, labeling, paperwork, and PPAP at a minimum).

C. Palletization / Unitization
To ensure optimization during transport and storage, the Supplier’s palletizing pattern shall comply to the
following items: edge-to-edge container alignment (vertical surfaces) with a complete flat top-layer
(horizontal surface).
When ordered quantities are less than a unit-load pallet, Delphi will accept partial-load and mixed-load
pallets (where more than one part number is shipped on the same pallet to the same destination plant) under
these conditions: (1) partial layers are completed with empty boxes of the same footprint; (2) empty boxes
are identified as such; (3) mixed-load labels are applied; and (4) the packing slip and/or mixed-load
manifest details the number of empty boxes and number of containers for each part number. Use of an
over-pack (pallet-sized carton) to consolidate individual boxes to the same destination plant is acceptable.
The mixing of containers with different Delphi plants or delivery dock destinations on the same pallet is
prohibited. Mixing bulk and manually handled containers on the same pallet is prohibited. Brick stacking,
pyramid stacking, and containers overhanging the pallet are prohibited.
Full Pallet Mixed Pallet Brick Stacking Pyramid Stacking Overhang
Acceptable Acceptable Prohibited Prohibited Prohibited

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D. Securement Materials
Polyester strapping is required. At a minimum, containers shall be secured to pallet with two (2) lengthwise
straps plus two (2) widthwise straps. Any deviations to securement materials shall be approved in writing by
the Delphi PRP.
Stretch film shall be used on the unit-load to protect corrugated packaging from the environment. Stretch
film shall be linear low-density polyethylene (LLDPE) and clear in color to enable the barcode scanning of
labels. A minimum of four (4) turns/layers of stretch film, or the equivalent in performance, are required
around and encompassing each individual pallet/unit-load.
External pallet load bracing, when used with strapping and stretch wrap, provides additional stability.
Corner boards or edge protectors (minimum thickness of 5mm) are required when the unit load is shipped
internationally or does not meet the dynamic and static stacking requirements as defined in Section VI. E.
The four (4) horizontal corners shall be placed over the four (4) vertical corners. Adequate clearance
between the containers and the pallet edge is necessary to guarantee support for vertical corner-boards.
Metal (nails, screws, strapping, buckles, clips, etc.), glue, and unitizing adhesives to secure loads to pallets
are prohibited. Polyvinyl chloride (PVC) stretch film is prohibited due to environmental reasons. Wire-
bound wood pallet boxes or wood crates are prohibited.

Acceptable Unacceptable Prohibited

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IX. SUPPLIER PORTAL

Supplier is responsible to connect, monitor, and respond to information on Delphi’s Supplier Portal and Delphi
Problem Solver. All Supplier manufacturing locations are required to register to Delphi Problem Solver as a
requirement for conducting business with Delphi. Problem Cases are used to communicate issues, initiate corrective
action, and facilitate problem resolution. Supplier suggestions may be submitted by using the Supplier Change
Request process.

X. CHANGE MANAGEMENT
Changes to the part design during the development process may trigger packaging-related changes. Any
modifications related to the pack structure, quantity, or system need to be communicated to the Delphi PRP and costs
discussed with the Buyer. Delphi encourages the Supplier to send photographs to assist in clarifying specific
questions/suggestions/proposals/concerns. All proactive and reactive changes shall be tracked using the Change
Request process.

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XI. CHECK YOURSELF

These questionnaires were developed to aid the Supplier in self-assessing its compliance to the Delphi Technologies
Global Packaging and Shipping Requirements Manual during Design/Approval and in Production.
If your answers are not ‘YES’, immediately correct the issue and/or contact your Delphi Packaging Responsible
Person (PRP) if assistance is required.

STAGE: Design and Approval (for Quotes and Changes)

Section
# Packaging Self-Assessment Questionnaire True False
Reference
Contact with the Delphi PRP has been established and Supplier
1. III.
understands Delphi Packaging and Shipping Requirements.
An approved standard container and pallet have been selected from
2. the Delphi Standard Container and Pallet Menu or an alternate has V.
been authorized for quote/design by the Delphi PRP.
Supplier’s pack and system design meets Delphi’s design criteria and
3. VI.
value stream requirements.
Supplier’s packaging system design was submitted to Delphi’s Buyer
4. V.
with the Request for Quote or Change Request.
Formal approval for Supplier’s packaging system design was granted
5. by the Delphi PRP and/or Delphi Buyer; the Supplier Packaging III.
Information Form utilized.

STAGE: Production Packaging and Shipping Compliance

Section
# Packaging Self-Assessment Questionnaire True False
Reference
1. Unit-load meets required stack height and weight limitations. VI. E.

2. Achieve 90% container density. VI. F.

3. Pallet meets required construction elements and ISPM15 requirements. VI. G.

Dangerous Goods are properly classified, packaged, marked, labeled,
4. VII.
placarded, documented, and shipped.
5. Container/pallet labels are applied per labeling requirements. VIII. A.

6. Proper shipping paperwork is provided. VIII. B.

Unit-load is properly palletized (containers aligned edge-to-edge and
7. VIII. C.
have complete flat-top layer).
8. Mixed loads contain material for only one destination plant. VIII. C.
Unit-load is properly secured with polyester strapping, stretch film (for
9. VIII. D.
corrugated), and corner boards (if international or when necessary).
10. Prohibited items are avoided; e.g., metal, ‘Do Not Stack’ label, etc. VI. &VIII.

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XII. STANDARD CONTAINER AND PALLET MENU

A. Delphi Technologies plants in the Europe, Middle East, and Africa
(EMEA) region align with VDA and Galia container and pallet
dimensions (* preferred inbound)
External Dimensions External Dimensions
EMEA Pallets Metric System (mm) Imperial System (inches) Important Notes
Common Name / Type Length Width Note Length Width Note
European Pallet (EUR)* 1200 800 47.24 31.50 For Returnable and
Expendable
Industrial Pallet (IND)* 1200 1000 47.24 39.37
Containers
1000 600 39.37 23.62
Alternate Pallet: Expendable
1140 980 IMCK160 45.00 38.50
Prior approval required Containers only
800 600 31.50 23.62
Reel Pallet 1200 600 47.24 23.62 Reels only

EMEA Returnable External Dimensions External Dimensions Containers/Layer by

Containers Metric System (mm) Imperial System (inches) Pallet Type
Standard Code Length Width Height Length Width Height EUR IND
VDA KLT 3214 300 200 148 11.81 7.87 5.83 16 20
VDA KLT 4314 400 300 148 15.75 11.81 5.83 8 10
VDA KLT 4328 400 300 280 15.75 11.81 11.02 8 10
VDA KLT 6428 600 400 280 23.62 15.75 11.02 4 5
Odette Galia 3212 300 200 114 11.81 7.87 4.49 16 20
Odette Galia 4312 400 300 114 15.75 11.81 4.49 8 10
Odette Galia 4322 400 300 214 15.75 11.81 8.43 8 10
Odette Galia 6422 600 400 214 23.62 15.75 8.43 4 5
Odette Galia 6423 600 400 214 23.62 15.75 8.43 4 5
Odette Galia 6432 600 400 314 23.62 15.75 12.36 4 5
Odette Galia 6433 600 400 314 23.62 15.75 12.36 4 5

EMEA Expendable External Dimensions External Dimensions Containers/Layer by

Containers Metric System (mm) Imperial System (inches) Pallet Type
Standard Code Length Width Height Length Width Height EUR IND
Odette Galia A16 300 200 125 11.81 7.87 4.92 16 20
Odette Galia A15 300 200 200 11.81 7.87 7.85 16 20
Odette Galia A14 400 300 150 15.75 11.81 5.90 8 10
Odette Galia A13 400 300 200 15.75 11.81 7.87 8 10
Odette Galia A12 400 300 300 15.75 11.81 11.81 8 10
Odette Galia A11 600 400 200 23.62 15.75 7.87 4 5
Odette Galia A10 600 400 250 23.62 15.75 9.84 4 5
Odette Galia A9 600 400 300 23.62 15.75 11.81 4 5
IMC100 DPN 28139123 560 480 240 22.05 18.90 9.45

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 Delphi Technologies Global Packaging and Shipping Requirements Manual

External Dimensions External Dimensions Containers/Layer by

EMEA Special
Metric System (mm) Imperial System (inches) Pallet Type
Container Types Length Width Height Length Width Height EUR IND
Bulk Container 800 600 465 31.50 23.62 18.31 2
Bulk Container 1200 1000 860 47.24 39.37 33.86 1
Bulk Container 1200 1000 975 47.24 39.37 38.39 1
Reel Container (only with
600 600 varies 23.62 23.62 varies 2
acceptable Reel Pallet above)

B. Delphi Technologies plants in the Nor th America (NA) region align

with AIAG and ISO container and pallet dimensions (* preferred inbound)

External Dimensions External Dimensions

NA Pallets Metric System (mm) Imperial System (inches) Important Notes
Common Name / Type Length Width Note Length Width Note
Automotive Pallet (AUTO)* 1219 1143 48 45
Industry Standard (ISO) 1219 1016 48 40 For Returnable and
1170 610 46 24 Expendable
Alternate Pallet:
1140 980 45 38 ½ Containers
Prior approval required
915 810 36 32
Fastener Industry Pallet 810 760 32 30 Fasteners only

NA Returnable External Dimensions External Dimensions Containers/Layer

Containers Metric System (mm) Imperial System (inches) by Pallet Type
Standard Length Width Height Length Width Height AUTO
Manually Handled 305 191 102 12 7½ 4 24
Manually Handled 305 381 102 12 15 4 12
Manually Handled 305 381 191 12 15 7½ 12
Manually Handled 610 381 102 24 15 4 6
Manually Handled 610 381 191 24 15 7½ 6
Manually Handled 610 381 280 24 15 11 6
Manually Handled 610 381 369 24 15 14 ½ 6
Manually Handled 610 572 191 22 22 ½ 7½ 4
Manually Handled 610 572 280 24 22 ½ 11 4
Manually Handled 610 572 369 24 22 ½ 14 ½ 4

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 Delphi Technologies Global Packaging and Shipping Requirements Manual

NA Expendable External Dimensions External Dimensions Containers/Layer

Containers Metric System (mm) Imperial System (inches) by Pallet Type
Delphi
Standard Length Width Height Length Width Height AUTO
Reference #
RSC Fastener 229 229 102 9 9 4 25
RSC Fastener 229 229 153 9 9 6 25
RSC 22224727 305 191 102 12 7½ 3¾ 24
RSC 22224728 305 381 102 12 15 3¾ 12
RSC 22224729 305 381 191 12 15 7½ 12
RSC 22224730 610 381 102 24 15 3¾ 6
RSC 22224731 610 381 191 24 15 7½ 6
RSC 22224732 610 381 280 24 15 11 ¼ 6
RSC 22224733 610 381 369 24 15 14 ½ 6
RSC 22224734 610 572 191 24 22 ½ 7½ 4
RSC 22224735 610 572 280 24 22 ½ 11 ¼ 4
RSC 22224736 610 572 369 24 22 ½ 14 ½ 4
HSC 22224737 281 189 93.7 11 11ൗ16 7 7ൗ16 3 11ൗ16 24
HSC 22224738 281 200 93.7 11 11ൗ16 14 7ൗ8 3 11ൗ16 12
HSC 22224739 281 200 187.3 11 11ൗ16 14 7ൗ8 7 3ൗ8 12
HSC 22224740 595.3 200 93.7 23 7ൗ16 14 7ൗ8 3 11ൗ16 6
HSC 22224741 595.3 200 187.3 23 7ൗ16 14 7ൗ8 7 3ൗ8 6
HSC 22224742 595.3 200 281 23 7ൗ16 14 7ൗ8 11 1ൗ16 6
HSC 22224743 595.3 200 374.7 23 7ൗ16 14 7ൗ8 14 ¾ 4
HSC 22224744 595.3 566.7 187.3 23 7ൗ16 22 5ൗ16 7 3ൗ8 4
HSC 22224745 595.3 566.7 281 23 7ൗ16 22 5ൗ16 11 1ൗ16 4
HSC 22224746 595.3 566.7 374.7 23 7ൗ16 22 5ൗ16 14 ¾ 4
HSC Cover 22224747 325.4 198.4 50.8 12 13ൗ16 7 13ൗ16 2
HSC Cover 22224748 406.4 306.4 50.8 16 12 1ൗ16 2
HSC Cover 22224749 623.9 387.4 50.8 24 9ൗ16 15 ¼ 2
HSC Cover 22224750 623.9 576.3 50.8 24 9ൗ16 22 11ൗ16 2
HSC Cover 22224751 1219.2 1143 76.2 48 45 3

External Dimensions External Dimensions

NA Special
Metric System (mm) Imperial System (inches)
Container Types Length Width Height Length Width Height
Bulk Container 813 762 635 32 30 25
Bulk Container 813 765 864 32 30 34
Bulk Container 1219 1143 635 48 45 25
Bulk Container 1219 1143 864 48 45 34

C. Delphi Technologies Plants in the Asia Pacific and South America

regions may align with either the EMEA or NA standard menus, please
contact the PRP for requirements.

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 Delphi Technologies Global Packaging and Shipping Requirements Manual

XIII. GLOSSARY
Materials capable of attaching one surface to another. Used in conjunction with fibre boxes; a material to glue plies
Adhesives of solid fibreboard, to glue facings to corrugating medium in combined corrugated board, to glue the overlapping
sides of a box forming the manufactures joint, or to glue the flaps in closing a slotted box.
Box See CONTAINER.
A corrugated or solid fibre box manufacturing establishment which has equipment to score, slot, print, and join
Box Maker corrugated or solid fibre sheets into boxes; equipment is regularly utilized to produce commercial quantities of fibre
boxes.
Brick Stacking The act of alternating the stacking of containers on pallets; length by width and width by length. NOTE: Prohibited.
The resistance of a material to bursting expressed in pounds per square inch. Burst strength depends on the tensile
Burst(ing) Strength
strength and extensibility of the material. It is typically determined using the Mullen burst test.
Carton See CONTAINER.
A statement printed on a corrugated Box Maker’s fibreboard box guaranteeing that all construction requirements
Box Manufacturer’s
have been observed and providing specific information about the container. The information allows the user to
Certificate (BMC)
identify and locate the box maker.
Closure The method used to seal a container once the parts have been packaged within it.
A rigid object having closed faces and completely enclosing its contents. It may be constructed of expendable or
Container
returnable materials. Also known as a box or carton.
A feature molded into the bottom of returnable manually handled containers that allow a larger container to stack on
Cross Stack
top of smaller containers.
Deck The horizontal load-carrying or load-bearing surface of a pallet.
Deck Opening Any void in the deck caused by the spacing of surface elements or a cut-out in a solid deck pallet.
Deckboard The surface element used in the construction of a pallet deck.
Density Quantity of mass per unit volume.
Depth See WIDTH.
DSPA Direct Sourcing Process Application; the system Delphi uses for sourcing.
Distribution The entire material flow process from the start of the supply chain (supplier) until the material is used (destination
Environment point-of-use).
DUNS Number A code assigned to manufacturers by Dun & Bradstreet; typically nine (9) digits in length.
Dunnage Devices or materials used to hold, secure, or protect goods during shipment.
Expendable A pack that makes only one trip; typically made of corrugated material.
A corrugated board test to determine the force that will crush a standard size of board standing on an edge. ECT
Edge Crush Test (ECT)
indicates the probably compression strength of the container made from the board.
Footprint The outermost dimensions (length and width) of a pallet, container, or container system.
Four-Way Pallet A pallet constructed to allow insertion and withdrawal of handling equipment from all four sides of the pallet.
A bulk corrugated packaging solution for the transport and storage of bulk cargo such as granular, powder, and other
Gaylord
loose-fill products.
Goods Parts, Pieces, Materials, or Items being purchased from the Supplier by Delphi.
Gross Weight The total weight (mass) of the goods plus the packaging; [Net Weight + Tare Weight = Gross Weight].
Height The vertical distance of a three-dimensional shape (y-axis) measured perpendicular to its length and width.
Half-Slotted
A corrugated container with four sides and no flaps; it requires a separate lid.
Container (HSC)
International Standard for Phytosanitary Measures, publication #15 – Regulation of Wood Packaging Material
ISPM 15 (WPM) in International Trade. ISPM 15 requires treatment of all wooden packaging and the application of a special
mark for the type of treatment utilized.
The part of the container where the ends of the scored and slotted blank are joined together by taping, stitching, or
Joint gluing. May be accomplished in the box manufacturer’s plant (manufacturer’s joint) or at the time the box flaps are
sealed in a box user’s plant (user’s joint).

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 Delphi Technologies Global Packaging and Shipping Requirements Manual

Length The longest horizontal dimension of a three-dimensional shape (x-axis).

Mixed Load When more than one part number is shipped on the same pallet.
Net Weight The weight (mass) of the goods without packaging.
A bulk corrugated packaging solution for the transport and storage of bulk cargo such as granular, powder, and other
Octabin
loose-fill products.
Overhang The portion of the unit-load that exceeds either the length or width dimension of a pallet. NOTE: Prohibited.
Pack Unit Quantity See STANDARD PACK QUANTITY.
Pack Validation The process used to verify/test the basic functions of containment and protection of a unit-load or container.
A corrugated or solid fibreboard sheet (or other authorized material) used for extra protection, separating tiers, or
Pad
separating layers of items when packed for shipment.
A horizontal platform used as a base for assembling, storing, handling, and transporting materials and products in a
Pallet
unit-load.
PC/CR Problem Case / Cost Recovery.
An easy-release label or card-holder area affixed to a container for the placing a label or Kanban card. In
Placard Dangerous Goods/Hazardous Materials, a placard is a diamond-shaped sign that identifies the class of the goods on
large containers; e.g., vehicle, rail car, cargo tank or bulk container.
PPAP Production Part Approval Process.
Primary Container The smallest shippable container closest to the parts (same as the STANDARD PACK).
Returnable A pack that makes multiple trips; typically made of molded plastic material.
When the container design considers the entire material flow from the start of the supply chain (supplier) until the
Rightsizing
material is used (destination point-of-use) and optimizes space requirements.
Regular Slotted A corrugated container where all flaps have the same length and the two outer flaps (typically the lengthwise flaps)
Container (RSC) are one-half the container’s width, so that they meet in the center of the box when folded).
Score An impression or crease in corrugated or solid fibreboard to locate and facilitate folding.
The junction created by any free edge of a container flap or wall where it abuts or rests on another portion of the
Seam
container where it may be fastened by tape, stitching, or adhesives in the process of closing the container.
Secondary Container The larger container on which multiple primary containers are shipped; typically it is the pallet.
Specialized
Packaging designed for a particular purpose or type of item.
Packaging
Standard Pack The smallest shippable container closest to the parts (same as the PRIMARY CONTAINER).
Standard Pack
The number of pieces in a primary container.
Quantity (SPQ)
Stitching Machine formed fastening to form the joint or close a box; typically of wire or thread from a spool.
Stapling Application of metal fasteners to form the joint or close a box. NOTE: Prohibited.
Stretch Film / Stretch film or stretch wrap is a highly stretchable plastic film that is wrapped around containers and pallets to protect
Stretch Wrap containers from the environment.
A continuous longitudinal board member of a pallet that supports the horizontal load-carrying or load-bearing
Stringer
surface.
A strip of cloth, plastic, or paper coated on one side with an adhesive. It is used to form the joint, close, or reinforce a
Tape
fibreboard box.
Tare Weight The weight (mass) of the packaging without the goods.
Top Deck The top surface of a pallet deck, oriented perpendicular to the stringer.
The total/overall height of the stacked primary containers plus the pallet (secondary container); measured from the
Unit-Load bottom of the secondary container to the top of the highest primary container. For bulk containers, it is the height of
the secondary container.
Weight Limit (Weight The weight under which the loaded container poses a low risk of injury to an employee. If the container exceeds its
Trigger) weight limit, further analysis is required.
Width The shorter horizontal dimension of a three-dimensional shape (z-axis); may also be known as depth.

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 Delphi Technologies Global Packaging and Shipping Requirements Manual

XIV. REVISION HISTORY

Release Date Revision Comments
Revisions throughout the manual to reflect new company name, Delphi Technologies
Jan 2018
(formerly Delphi). Contact your Delphi Technologies buyer with any questions.
Complete revision to entire manual: update formatting, streamline text,
incorporate lessons learned, and remove redundancies; reduced length.
Added Packaging workflow charts to depict New Part Sourcing, Container
Selection, and Change.
Added ‘Quick Start Menu’, ‘Check Yourself’ assessment, requirement for polyester
strapping, and visual aids to define acceptable, unacceptable, and prohibited
June 2017 examples.
Incorporated EMEA special packaging system specifications, heavy pallet-load
label example, container utilization %, and KLT + Galia container information, thus
obsoleting the Packard ‘Golden Rules’ Packaging Guideline.
Modified Supplier Portal section, moved Revision History to end.
Removed: Forward, Section 11 (Packaging Examples), and superfluous sections of
Section 12 (Recycling Information).
Added: RFQ Packaging Requirements
Revised: Introduction, Packaging Development and Approval, General
Requirements, Expendable Packaging Systems, Export/Import Requirements,
Returnable Packaging Systems, Internal Dunnage, Shipping Labels, Mixed Labels,
January / May
Shipping Partial Layers, Recycling Information, Packaging Container Menus,
2015
Glossary of Terms, and Forms and Supplement Requirements.
Removed: Cube Utilization Calculation and Attachment, Supplier Packaging
Checklist, Supplier Shipping Compliance Checklist, Packaging Receiving Checklist,
DSPA Example, and Delphi Regional Office Information.
Remove SPI and added DSPA.
February 2014
Additional miscellaneous revisions.
November 2011 Revised International Container listing.
Both Regular Slotted Cartons (RSC) and Half Slotted Cartons (HSC) are allowed.
Revised ergonomics section – minimum container weights determined by weight
triggers.
Standards cover all Delphi operations, globally.
Hand-holds for manually handled expendable cartons are now optional unless
specified by receiving division/location.
Partial layer guidelines provide for suppliers when ship quantity is not in level
May 2007 layers.
Standard pack menu for expendable cartons revised to better cube the pallet.
Increased maximum load height from 50” to 52”.
Prohibit ‘Do Not Stack’ labels and signs; loads shall be stackable.
Shipping standards included for Lean Logistics Network.
Deviation to manual requires approval from Delphi Divisional Inbound Packaging
Leader.
Added: Standard Pallet Menu, Audit Checklists.

Delphi Technologies / Page 21