The ability to deliver parts directly to the assembly line is an important ingredient for gaining the speed and savings associated with lean manufacturing. Returnable containers make lineside delivery cost effective.

The Ford Motor Company has recently completed a selection process to define ideal returnables for use by the automaker and its Tier 1 suppliers. Ford believes that using more returnable containers will eliminate contamination from corrugated dust, reduce overall inventories, increase shipping densities, reduce the amount of stored materials, save container and shipping costs, and reduce corrugated waste.

Ford uses more than 100 suppliers for the Taurus/Sable and small truck transmissions built at its Livonia, Mich. plant. These include producers of fasteners, seals, gaskets, plates, and pistons, among others. Right now about 70% of the parts arrive in returnable containers.

"We want 100% returnables. That is our goal," says Howard Heath, synchronous material flow coordinator. "We want to reduce the risk of corrugated contamination that can cause problems with transmission assembly."

Ford selected the models of containers it wishes its suppliers to use, then negotiated volume pricing with the container manufacturers. The Tier 1 suppliers then purchase the containers, while Ford manages the supplier loops.

One of the new returnable containers selected for shipping Livonia's transmission parts is comprised of a plastic pallet and a top lid system designed to hold cross-stacking totes (Cookson Plastic Molding, 518-783-3194, www.cooksonmhd.com). The system has a smaller footprint than a standard auto pallet, 32 x 38 inches, and uses seatbelts to hold the load in place.

"The smaller footprint allows us to save space," says Jay Dunkerley, Ford's supervisor of packaging and material handling engineering. "Before, we had received a lot of small materials, such as fasteners, that were less than a layer on a standard pallet – only 4 or 5 totes. The new system cubes better."

One supplier using the new container is Nichols Portland, a division of Parker Hannifin Corp., in Portland, Maine. The company manufacturers small gerotor parts that pump fluids throughout the transmissions. The gerotors are placed into pre-formed trays and totes, with 30 units per tote. Forty-two totes are cross-stacked seven levels high on the pallet, then belted and stretch wrapped to secure the 1,400 pound load. The new system replaces corrugated cartons and wooden pallets that were previously used for shipping.

"I like having the smaller footprint. The employees are more comfortable transporting the smaller load within our plant," says John Mancini, dunnage coordinator for Nichols Portland. "We expect this product to be very durable."

The smaller footprint is also easier to maneuver on the ergonomic lift tables used for packing at Nicholas Portland and fits better into the storage racks than a conventional 45 x 48 inch auto pallet would. The company ships Ford 22 pallet loads weekly. Upon arrival at Ford, the containers are either taken directly lineside or stored in adjacent racks.