Pallets for automotive suppliers
Supplier docks are where most of Metro Detroit's pallets turn over. They ship on the 48 x 45 and the 48 x 40, often on four-way or block builds, and they want the same stack on the same day each week.
The supplier base behind the plants
Michigan ranks first in the nation for automotive manufacturing jobs, at six times the national average concentration, and 1.1 million automotive or mobility jobs make up 20% of the state's workforce. 98 of the top 100 automotive suppliers to North America have a presence in the state, and 65 are headquartered there. Those numbers come from the Detroit Regional Chamber; the state's own development agency counts 96 of the top 100 and 60 headquartered, so treat the exact figures as close rather than fixed.
Each one of those suppliers ships parts to a plant, and each shipment rides a pallet. The region produces 1.7 million vehicles a year and hosts 25 OEM headquarters and tech centers, so the flow of pallets is steady and the sizes are predictable.
What a supplier dock ships on
| Need | Usual answer | Why |
|---|---|---|
| Size | 48 x 45 and 48 x 40 | The 48 x 45 is the size listed for the automotive industry; the 48 x 40 is the default everywhere else, and many docks see both |
| Build | Block or four-way | Crowded cells and lift-truck traffic reward a pallet that can be picked up from any side |
| Grade | Grade B for outbound, Grade A for automated lines | Repairs are fine on most parts; edges must be clean where a robot reads the pallet |
| Rhythm | Weekly or per shift | Parts move on schedules, so pallets do too |
Where in the metro
- Oakland County. Troy hosts supplier headquarters such as Aptiv, Magna Powertrain and Meritor; Auburn Hills has facilities of more than 50 automotive companies; Southfield is home to Lear, Denso and Federal-Mogul offices. Troy, Auburn Hills, Southfield.
- Wayne County. Livonia has ZF and Roush; Canton Township has Yazaki's North American headquarters; Van Buren Township has Visteon. Livonia, Canton Township.
- Macomb County. Warren and Sterling Heights sit beside the assembly and technical centers. Warren, Sterling Heights.
Why a program beats a one-off
A supplier dock that clears a trailer of pallets once is solving a problem. One that clears the same stack every Thursday has a process. A buyer can plan around the second kind: a recurring pickup, a known size and grade, a known count. That is the idea behind dock programs, which cover buying and clearing on a schedule.
Mixed sizes are the usual mess
Because a supplier may ship to one customer on 48 x 45 and to another on 48 x 40, returned and received pallets pile up mixed. A rough split by size before pickup is the single most useful thing a dock can do. The comparison guide shows how to tell them apart quickly, and the sorter walks through a mixed pile.
Cross-border parts
Suppliers that ship into Ontario should look at pallets to Canada. The current rule exempts wood packaging from the continental US, but the rule is changing in phases, so check before a lane starts.
Buying and selling
A supplier can be on either side of the market in the same week: buying a block pallet for a new part number and clearing a stack of cores from the receiving dock. Buy used pallets, new and custom or sell used pallets.
Questions from supplier shipping leads
We get audited on packaging. Does the pallet grade matter?
It can. Many customers specify a pallet in their packaging requirements, covering size, entry and stamp. Where the requirement names a grade, follow it. Where it only names a size, a sound Grade B is usually acceptable, but confirm with your customer rather than assume.
A customer returns our pallets on loan. Can we sell them?
Not if they belong to the customer. Loaned pallets circulate in a closed loop and are not yours to sell.
How do we handle a run that suddenly stops?
A program ending leaves a dock full of pallets sized for it. Describe the stack, say it is a one-off, and ask for a single clearance.
Is a weekly pickup too frequent?
For a supplier with daily shipments, weekly is normal. Dock space is the limit, and most docks cannot hold more than a week's empties anyway.
Reading your own dock
Two numbers describe a supplier dock well: how many pallets come in per week, and how many go out. If more come in than go out, the dock is a net source of empties and the question is clearing. If more go out than come in, it is a net buyer. Many suppliers are both at different times of year, which is why buying and selling belong together.
What a first message should say
Name your supplier tier if you know it, the customer plants you ship to, the sizes you use and the weekly count. That sketch tells a buyer more than a long paragraph.
Peaks and troughs
Model changeovers and plant shutdowns shift pallet flow. Before a launch, parts ramp up and empties pile; after a program ends, stock is left over. Warn a buyer in advance of both.
Closed loops
Some programs use returnable pallets that never enter the market.