01Define every packaging level
Draw the hierarchy from component bag to retail package, inner pack and shipping carton. Give each material an identifier, dimensions or fit reference, material description, print revision and quantity. State which components are loose and how movement is controlled during handling.
02Connect bags to the BOM
Create a bag allocation table using part identity, color, quantity and bag number. Reconcile bag totals with the approved bill of materials and permitted spares. If numbered bags follow assembly stages, confirm that the instruction steps use the same sequence and numbering.
03Control inserts and instructions
List the exact instruction booklet, addendum, sticker sheet, promotional insert and other paper components. Record language and revision. Place them where they arrive readable and undamaged, and ensure a temporary insert is not silently carried into mass production.
04Review images and factual statements
Compare the package model, colors, included pieces, stated count, feature descriptions and accessory presentation with the approved sample and BOM. Qualify lifestyle props and alternative builds clearly. A statement should be supported before print, not justified after cartons are produced.
05Check market-specific information
Record target country and review the responsible business identity, model reference, age presentation, warnings, tracking data and other required information with qualified market advisers. Check visibility, permanence and consistency across item, package and instructions rather than copying another product's panel.
06Test the physical pack-out
Pack counted production-intent contents using the proposed materials and sequence. Inspect closures, crushing, abrasion, part migration and instruction damage after defined handling or transport tests. Record the test method and limitations; one informal drop does not establish distribution performance.
07Freeze files and line controls
Approve die lines, print files, color references, bag plan and pack-out photographs together. At packing, use first-off checks and reconciliation of issued versus packed components. Quarantine mixed revisions and document rework so an old instruction or label cannot enter an approved batch.