BMS-0000005 PACKAGING REQUIREMENTS REVISION 06

1. PURPOSE / SCOPE:
This document provides the minimum general packaging requirements for the packaging of
product shipped to any worldwide Tesla Motors manufacturing, warehousing, and distribution
facility. For Off the Shelf (OTS) the OEM (Original Equipment Manufacturer) packaging is
acceptable.

2. INFORMATION / DEFINITATION / REFERENCE:

Code of Federal Regulations Title 49 (CFR 49), must conform to all requirements of CFR 49.
BMS-0000002 Serial Number Labeling Instruction
BMS-0000003 Package Label
BMS-0000151 Definition of Traceability Grades and Serial and Batch Numbering
Guidelines
IPPC International Standard for Wood Packaging - ISPM 15 - Summary of Requirements by C
•General Administration of Quality Supervision, Inspection and Quarantine Of People’s Republic
of China
www.aqsiq.gov.cn
•Certification and Accreditation Administration of the People’s Republic of China
ww.cnca.gov.cn
•Standardization Administration of the People’s Republic of China
www.sac.gov.cn
•State Food and Drug Administration
www.sda.gov.cn
•Ministry of Health of the People’s Republic of China
www.moh.gov.cn
•Ministry of Commerce of the People’s Republic of China
www.mofcom.gov.cn
•State Environmental Protection Administration of China
www.zhb.gov.cn
•State Tobacco Monopoly Administration
www.tobacco.gov.cn
•General Administration of Customs of the People’s Republic of China
www.customs.gov.cn
•Country for Wood Packaging Materials - October 1, 2009

3. DOCUMENT OWNER:
Material Planning

Responsibility: This procedure applies to all team members in Tesla Facilities that have an
impact specified in the scope of this document.

4. SUPPLIER RESPONSIBILITY AND COMPLAINCE

This document does not eliminate any supplier packaging responsibility. It is the supplier’s
obligation to make sure that the packaging complies with all local, federal, and international laws

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and regulations. These rules and laws include export shipments as well as transportation
requirements and regulations pertaining to hazardous materials.

It is the supplier’s responsibility to determine the most economical method of packaging,

consistent with these requirements, unless otherwise specifically instructed. Without
compromising safety to the individual, the primary goal for supplier packaging is to
provide damage-free delivery of both the container and its contents from the point of
manufacture and origin to their point of delivery, use and installation.

To ensure supplier conformance, all shipments are subject to inspection. Tesla Motors reserves
the right to reject any shipment which is not in compliance with these specifications.

5. PACKAGING
5.1 Package testing
Package performance is critical to maintaining part integrity during the shipping phase. Tesla
Motors requires that the product packaging be able to withstand the normal hazards seen during
the distribution environment, such as vibration, shock, compression, and impacts.

5.1.1 Vibration
Vibration is the one hazard element that will occur during every handling and
transportation phase of a distribution cycle. It is also the one element that is most
difficult to understand without performing product vibration testing. Essentially,
the package materials that are chosen for a specific product must, ideally,
attenuate the forcing frequencies seen in the distribution cycle which are close or
match the natural frequencies the product may have.

5.1.2 Shock(s)
Shocks (drops) are a common hazard element that may occur in the distribution
cycle. Essentially, a packaged product will see drop height that correlate to the
size and weight of the package product. Typically, the smaller the package the
higher the drop height that may occur.

The following table shows packaged product weights with typical corresponding
drop heights that may occur during the distribution cycle. The supplier must
adequately package the product to prevent damage occurring at these drop
heights.

Packaged Product Weight Drop Height

(pounds) (inches)
0-10 42

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11-50 36
51-100 24
101-250 18
251 + 12
Palletized Loads 6
Table 5-1: Typical Drop Heights

5.1.3 Compression
There are two types of compression, static compression and dynamic
compression. Static compression comes from warehousing and storage while
dynamic compression stems from compressive forces incurred during
transportation and material handling.

The package or container should prevent damage, due to static compression, to

the product when stacked 2 pallets loads high or 96 inches for a period of 30
days without any visible degradation to any package or its content. The package
or container must also be able to withstand the dynamic compressive forces, due
to shock and vibration, normally incident to the distribution environment when
stacked 2 pallet loads high, or if not palletized to a height of 96 inches.

5.1.4 Impact
Impacts can be regarded as horizontal shocks. Impacts are common to the rail
industry during rail car coupling and in other environments during the sorting of
packages. The supplier package should be designed to withstand impacts
normally incident to the distribution environment. Special attention should be
placed on packages that are being shipped by small parcel shippers. The small
parcel environments are extremely hazardous during the sorting process, and
impacts to the packaged product can come from any and all directions.

5.2 Ultraviolet Light

Degradation of polymeric materials can occur due to breakdown of long carbon chains by
ultra violet (UV) light from sunlight or manmade light sources, notwithstanding chemical
additives that help prevent UV light degradation. This type of degradation should not be
evident on any parts upon receipt, installation, and use. Though most parts will be used
within a relatively short period of time after being packaged, the possibility exists that they
main remain packaged for a longer period, such as spare parts. When applicable, the
supplier shall prevent this type of degradation by packaging the product in a non-light
penetrating material which will resist or prevent degradation for the maximum period of
time.

5.3 Temperature
In the distribution environment, products may be exposed to temperature extremes ranging
from 20º F to 140º F. Packaging exposed to extreme temperatures may degrade the

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package performance. Even at extreme temperatures, the supplier must select packaging
materials which effectively protect the product from handling damage

5.4 Humidity / Moisture & Reactive gases

Humidity is one of the most important environmental factors and is relevant to a wide range
of products. Components/products are degraded due to absorption of water molecules or
corrosion by water. The supplier must prevent the corrosion of metal, which begins after
the humidity reaches a specific limit

Reactive gases, such as oxygen can react with surfaces of products, resulting in discolored
or tarnished appearance. To prevent corrosion degradation from occurring, the supplier
must either eliminate or reduce the amount of reactive gas molecules in packaging

There are three methods available which the supplier should utilize to prevent degradation:
the use of desiccant, the use of vapor corrosion inhibitors, and the use of a non-reactive
gas purge

5.5 Desiccant
Desiccants are typically the primary material used to reduce the moisture level in
packaging by absorbing water molecules from the environment. Acceptable barrier
materials include:

• Good: Polyethylene (4-6 mil) provides a good moisture barrier for parts which
are not extremely moisture –sensitive
• Better: Barrier materials which are manufactured to military standard MIL-B-
131. These are foil/polyethylene combination with various types of outside
layers (Tyvek, polyester, kraft paper)
Note: All ocean shipments require some form of moisture protection

5.6 Vapor Corrosion Inhibitors (VCI)

Vapor Corrosion Inhibitors (VCI’ s) are those products that emit a vapor which create a
very thin barrier on a part/product and act as a barrier between the product and water
molecules. VCI’ s are acceptable for use on non-electronic and non-critical surface
products

5.7 Non-Reactive Gas Purge

Purging the packaging with a non-reactive gas will adequately protect the part from
corrosion/degradation. Inert gases such as nitrogen, carbon dioxide, and argon can be
used to replace the normal air that contains water molecules inside the packaging

5.8 Electrostatic Discharge (ESD)

Electrostatic Discharge (ESD) is one of the most pervasive hazards for electronic
components. Since static discharge of less than 50 volts can damage an electronic
component, it is critical that the supplier handle these products in a static safe manner and
utilize packaging materials which protect the product against this hazard. Hazards include

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electromagnetic interference (EMI), and Radio frequency (RFI). When the product is
susceptible to ESD, EMI, and/or RFI damage, it is the supplier’s responsibility to determine
the type of packaging required to prevent damage

6. HAZARDOUS MATERIALS & CHEMICAL PACKAGING

All materials that meet the definition of hazardous materials as defined in the Code of Federal
Regulations Title 49 (CFR 49), must conform to all requirements of CFR 49 and the applicable
governing the mode of transportation by which the material will be shipped for shipments
originating in, or destined to, the United States of America. Civil and criminal penalties may be
imposed upon any shipper (supplier) for violating these government regulations.

CFR 49 specifies all of the required shipping papers, markings, labeling, and performance test
required for a shipment of hazardous material. The shipper (supplier) of hazardous materials
must meet or exceed the established hazardous material federal regulations. The following is a
list of applicable documents the have specific modal requirements:

▪ International Civil Aviation Organization (ICAO) Technical Instructions for the

Safe Transport of Dangerous Goods by Air
▪ International Air Transport Association (IATA) Dangerous Goods Regulations
▪ International Maritime Dangerous Goods (IMDG) Code
▪ United Nations Recommendations on the Transport of Dangerous Goods
For chemicals which are not defined as hazardous materials, Tesla Motors requires that Materials
Safety Data Sheet (MSDS) must be attached to every individual part shipped that contains a
chemical (including oil, greases, Loctite, lubricant, etc.)

7. ENVIRONMENTALLY RESPONSIBLE PACKAGING

7.1 Reusable Packaging

Reusable containers, crates and stillages are used to facilitate the shipment of product from
supplier site to manufacturing facilities and will then be returned to the original shipper or third
party. Tesla Motors supports the design and manufacturing and use of reusable packaging, as
long as it clearly meets safety and product protection requirements and established Return on
Investment (ROI) criteria.

In the absence of a formal return logistics program in MES at Tesla Motors or at the supplier
today, the design and reusability effort of a package is a joint effort between Tesla Motors and the
supplier. The involvement of each party is critical to fully support the logistics of using the
reusable packaging

Although individual reusable packs may require varying marking and labeling requirement, all
reusable packs should include at minimum;

1) Verbiage identifying it as a reusable package

2) Owner of the reusable package

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3) Return address for the reusable package

All marking and labeling should be highly visible, and should not interfere with any handling assist
devices, handling symbols, or handling instruction on the package

Prior to reuse, all reusable containers, crates and stillages should be refurbished, as necessary,
to a like-new condition. Any reusable item which can not be refurbished, and compromises safety
and product protection due to its degraded state, should be removed from the reusable packaging
system

7.2 Recycling
To reduce the amount of solid waste, suppliers should always strive to incorporate recycling into
their packaging designs. Such goals should include

o Use of packaging materials, which are easily recycled like paper and plastic corrugated,
polyethylene, polypropylene, and polystyrene
o Designing packages which allow the package components to be easily separated prior to
recycling, such as avoiding designs which bond two or more dissimilar materials
o Appropriate recycling symbols should be utilized on all recyclable materials

7.3 Source Reduction

Tesla Motors expects its suppliers to source reduce (minimize) packaging materials used in the
package design for Tesla Motors products, provided safety and product protection are not
compromised

8. PART AND PACKAGING CLEANLINESS

It is the supplier’s responsibility to understand the product cleanliness requirement prior to
packaging the parts

Unless the part cleaning requirements are otherwise stated in a contract, purchase order, drawing
or separate specification, the part should be, at minimum free of any visible contaminates (visibly
clean) including, but not limited to dust, corrosion, films and shavings

9. GENERAL PACKAGING REQUIREMENTS

Matched sets, bulk hardware items, and kits should be boxed together, but many require
individual containerization to prevent deformation or other damage during handling and shipment

Same parts must be packaged consistently from shipment to shipment, both in the containers
used and quantity of parts per container for a given number

Protect all bagging from punctures, abrasions, and protrusions which could lead to personal
injury, part damage, and part contamination during the handling and distribution cycle.

All studs must be capped and all sharp edges and corners protected to prevent damage to
personnel and/or other parts

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Ensure the packaging is safe to handling personnel, including, but not limited to protruding
staples, nails, and loose bending

The use of staples is prohibited, especially as method of closure

Parts must be adequately separated to prevent entanglement

Parts must be packed to prevent shifting/rubbing. If needed, separate parts to prevent damage

Packaging must not adhere to parts, nor produce part corrosion or oxidation

Packaging materials must be compatible with the parts contained within

Package should not be filled to the extent that they bulge or deform
Heavier parts should always be placed at the bottom of the container

Voids should be filled as required to prevent part shifting or movement within the package. Use of
loose-fill dunnage is not recommended

Do not overload a container whereby the weight exceeds the container’s designed capability

As required, use proper labeling to mark packages with special handling consideration such as
“Fragile”, “Handle With Care”, “This End Up”, and “Do Not Stack”, to name a few

Package closure should permit access to contents for inspection purpose without destroying the
container’s usefulness. For example, plastic bags should be sealed such that they can be opened
and re-sealed at least one time

All pallets should be of the 4-way entry variety

When the center of gravity (CG) is not in the center of the unit or unitized load, the location of the
CG shall be marked on all 4 sides to keep maintain load stability during material handling

All wood packaging must conform to the European Union Emergency Measures for Coniferous
Non-Manufactured Wood Packaging Material to prevent the spread of the Pinewood Nematode.
Refer to the Animal and Plant Health Inspection Service (a division of the United States
Department of Agriculture) for compliance requirements

All wood packaging must be free of the insects and insect infestation

10. PRIMARY PACKAGING REQUIREMENTS

10.1 Primary Packaging Purpose

The purpose of primary packaging is to facilitate proper identification of the part so as to
contain and reduce damage to the parts as it moves into the Tesla Motors manufacturing
space, or the ASO sites premature removal of the protective packaging can result in
handling damage to the part. The supplier must understand the logistics for their part to
help facilitate this purpose

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10.2 Bagging Specification

10.2.1 Materials Type
Natural Polyethylene: This material can be manufactured in many colors, but is
commonly clear. It should not be put in contact with static sensitive parts

Anti-Static Polyethylene: This material can be manufactured in many colors, but is

commonly pink. It should be utilized for parts which at minimum require static
insulation and dissipation

Nylon: This material typically used to bag items which are chemically cleaned. The
cleanliness level of nylon is higher than most bagging materials in regards to
surface particulate, out gassing, and mobile ions

Static Shielding: This material typically contains a carbon black or metalized

material and can sometimes contain a laminated ant-static polyethylene layer. It
should be utilized for parts which, at minimum, require static shielding

10.2.2 Material Thickness

Polyethylene bagging material thickness should be a minimum of 4 mil or a
maximum of 6 mil. If the bagged part weight is equal to or less than 10 lbs., 4 mil
bagging material should be used. If the bagged part weight is greater than 10
lbs.; then 6 mil bagging material should be used. Nylon bags should be a
minimum of 2 mil thick, while status shielding bags should be a minimum of 3 mil
thick

10.2.3 Bagging Methodology

It is imperative that the proper material type is selected. In general, use anti-static
and/or static shielding bags for ESD sensitive parts, nylon bags for Nylon bags
for chemically cleaned parts and natural polyethylene bags for all other parts. In
most cases, the bagging will remain around the part until the part’s point of use

10.2.4 Bag Sealing

In order to eliminate the possibility of product contamination, the preferred
method of bag closure is heat sealing. If heat sealing is not feasible, the bag
must be folded and tape sealed to make sure the bag opening and seams are
entirely sealed. Zip lock bags are acceptable as long as the meet the required
thickness (4-6 mil), and cleanliness level and strength characteristics. Under no
circumstance should the zip lock bag seal fail under normal handling and
transportation

10.3 Cushioning
Product packaging often requires “cushioning” for adequate product protection. When
cushioning material is required, proper material selection and design is essential in
providing damage free product. It is recommended that the supplier seek a packaging
professional experience with cushion design if necessary

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10.4 Pack Code and Packaging Determination Instructions

This section helps users determine the proper packing code for the part being shipped as
well as the specific primary packaging requirement per that pack code

To determine the pack code, review (Table 10.4.1), then match the pack code to the
Primary Packaging Requirement Matrix (Table 10.4.2)

After locating the pack code on the Primary Packaging Requirement Matrix, follow the
column from top to bottom to determine the packaging requirement

If a part meets the definition of more than one family, the requirements of all applicable
families should be met.

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Table 10.4.1 Part Family Pack Codes

Pack Code Part Families
100 Body Exterior and Carbon panels
101 Bumpers and Vac Formed panels
102 Lighting
103 Interior
104 Instrument Pack
105 Remote Keyless Entry
106 Tire Pressure Monitoring System
107 HomeLink
108 VDS
109 Switchpack
110 Navigating System
111 ESS Assembly
112 Battery Cells
113 TVSH
114 Customer Connector
115 High Power Custom Cables
116 HVAC
117 HVAC lines
118 Rotors
119 Rotor Rings
120 Shroud
121 Motor Cable
122 Motor
123 Encoder Assembly
124 Fan
125 Thermal Sensor
126 Bearing
127 Coupling
128 Power Electronics Module
129 Transmission
130 ABS Systems
131 Door beams and Extrusions
132 Sealing
133 Chassis Tub
134 Shifter Assembly
135 Drive Shaft
136 Low-voltage Wiring Harness
137 Printed Circuit Board (PCB) Assemblies
138 Programmed devise assembly (PROM) Resistors, Diodes, Integrated Circuits
139 Seals, Gas lets, O-rings
Fabricated parts, Fragile-Parts which possess plated, anodized, coated, painted or
140
treated critical surfaces which are easily damaged

140A Fabricated parts meeting description for pack code 140, with special surface cleanliness requirements for safety
critical adhesion joint
141 Fabricated parts, Non-Fragile
Assemblies - Fragile - Assemblies which possess plated, anodized, coated painted or
142 treated critical surfaces which are easily damaged
143 Assemblies - Non -Fragile orientation label required

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10.4.2 Primary Packaging Requirement Matrix

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10.5 General Packaging

10.5.1 If the supplier is currently packaging or receiving parts from their supplier
packaged as 1 each, do not change current packaging practice
10.5.2 All small parts listed below that are sold in “set” must be packaged in
individual sets (1-set per 1 bag or box)
10.5.3 If the small parts are purchased with a unit of measure (U/M) stated on
the purchase order, bag the part per that U/M
NOTE: All bags and boxes must be properly identified with proper bar code label per
procedure BMS-0000007. If applicable, and if space permits, additional labeling should
be utilized on the bags and boxes in the following order of priority

• Weight Label (generic)

• “Fragile” label (generic)
• Orientation label (generic)

10.6 Package Quantities

Follow the industry best practices as recommended by the suppliers

10.7 Hardware Packaging Requirements

General:

• All parts must have metal shavings, chips, etc. removed and cleaned prior to
packaging. It is essential that cleanliness levels attained during parts fabrication are
not degraded by the packaging
• Place like parts into a bag and seal the bag. Additionally, if the hardware contains
sharp points or protrusions, place part into a double bag or wrap parts in the bubble
cushioning before placing them into a second bag
• Do not overstuff the bag
• One bag of hardware shall not exceed 5 lbs. unless previously agreed. Bulk items
over 5 lbs. shall be split into several bags as accepted

11. SECONDARY PACKAGING REQUIREMENTS

11.1 Definition; “Secondary Packaging” is defined as any and all packaging and labeling used
after the primary packaging
11.2 Shipping Container Selection
It is the supplier’s responsibility to select the best container for the application. Though
there are many types of shipping containers (cartons, totes, cases, crates, etc.), the most
common containers for Tesla Motors products are cartons, crates, and totes

11.2.1 Special stillages are manufactured for components and modules which facilitate
the delivery of items to line side at the manufacturing facilities. The stillages are
designed and manufactured via joint effort between Tesla Motors and the
supplier
11.3 Outsourced Module & Sub- Assembly Packaging

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11.3.1 Outsourced modules and sub-assemblies must be at minimum, bagged and then
containerized. Packaging alternatives must be approved by Tesla Motors. Due to
often more complex nature of modules and sub-assemblies, package design
must particularly allow for safe, efficient, and damage-free removal of the product
from the container
11.3.2 Specification ESS shipping Crate – single unit
11.3.3 Specification PEM shipping crate – single unit
11.3.4 Specification PEM shipping Crate – three units
11.3.5 Specification Motor shipping Crate – single unit
11.3.6 Specification Motor shipping Crate – four units
11.3.7 Specification Transmission Shipping Crate – single unit
11.3.8 Specification Transmission shipping Crate – multiple units

12. HEAVY PACKAGE REQUIREMENTS

12.1 Handling and Labeling

Heavy packages should always incorporate features into their design which maximizes
safety and convenience when handling. Heavy packages should also be identified at both
primary and secondary packaging level so that proper handling and lifting choices can be
made to avoid personal injury and product damage

All primary and secondary packages equal or greater than 10 pounds are defined as
“Heavy”, and must be labeled with the exact package weight rounded up to the nearest
pound. One weight label package is required and must be placed in a highly visible
location on the package (usually next to bar code ID label). If the weight of the packaged
product remains consistent, the weight can be pre-printed on the container

Follow the instructions on the procedure BMS-0000003 for the specification of the weight
label

12.2 Top Heavy Labeling

When applicable, all individual containers must be labeled as “Top Heavy” on all four
sides near the center of the top edge. Labeling a container as top heavy indicates that a
higher potential exists that the container could tip over during the handling and
transportation. A container is designated as top heavy if it meets all of the following
criteria:

• ≥ 200 lbs.
• Height ≥ 48 inches
• Height ≥ 2X width dimension
• Center of Gravity (CG) higher than ½ the container height
If the CG is not known, label the container as top heavy if it meets the other three criteria
but its height ≥ 1.5 X the container width dimension

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The top Heavy label is an industry-common 3.00"x4.50" label which can be purchased
from a variety of sources including but not limited to packaging distributors

Figure 12-1: Top Heavy Label

13. BAR CODE LABELING REQUIREMENTS

All packages and shipments must be labeled in accordance with Tesla Motors labeling
specification BMS-0000003

14. REPAIRED, REWORKED & REFURBISHED PARTS PACKAGING

All repaired, reworked and refurbished parts shall be packaged and labeled per this specification
and the referenced documents herein

15. ASO PARTS PACKAGING

The primary goal of packaging for ASO parts headed for Tesla Motors service centers is the
same as that for incoming parts for Tesla Motors manufacturing – to provide damage –free
delivery of both the container and its content from the point of manufacture and origin to the point
of delivery, use and installation without compromise to individual safety. ASO parts packaging
shall conform to the requirements stated within this document unless otherwise noted.

All parts that are sold to ASO centers must be packaged in individual sets per the Tesla PO

16. REVISION HISTORY

Revision Level Date Description of Change

01 04/2011 Initial Release Legacy document number 99-000117-03

Pdf file format applied

02 08/2011

Pack Code 113 changed to TVHS

03 9/2011

Updated “x” for pack code matrix. Nylon and Poly bags and heat seal and
04 10/2011
tape indicated as optional. Corrected BMS-002 title and added BMS-151
Traceability to references.

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Updated pack code and description.

05 10/12/2015

Updated formatting of tables 10.4.1 and 10.4.2

06 03/28/2016

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