GM1738 GMTH - General - Req 2014

GMTH PACKAGING REQUIREMENTS
FOR PRODUCTION PARTS
LOCAL GM 1738GMTh
GMTh REGION
PACKAGING REQUIREMENTS
REVISION 6.0
GENERAL MOTORS (THAILAND) LIMITED

Global Supply Chain
October, 2014
GMTH- Revision 6: Oct 2014 Page 1 of 42

TABLE OF CONTENTS
REVISION LOG
1.0 Introduction 5
2.0 General Requirements 5
2.1 Small lot Packaging 5
2.2 Ergonomics guideline 6
2.3 Shelf life 7
3.0 General Requirements for expendable Packaging 7
3.1 Supplier Responsibility 7
4.0 Compliance Statements 11
4.1 Continuous Improvement 12
4.2 Packaging Costs 12
5.0 Expendable Container Shipping Systems 12
6.0 GM Global Intercontinental Expendable Carton Size and Construction 15
7.0 Global Intercontinental Standard Pallet Size and Construction 16
8.0 Loading of Cartons To Pallets 18
9.0 Modular Bulk Boxes Size and Construction 20
10.0 Dunnage, Closure and Securement 22
10.1 Internal Dunn age 22
10.2 Carton/Crate Closure 23
10.3 Securement – Container To Pallet 23
11.0 Acceptable Global Shipping Practices 24
12.0 Unacceptable Global Shipping Practices 26
13.0 Returnable Container/Rack Requirements 29
13.1 Supplier Requirements 29
13.2 Returnable Systems 29
13.3 Dunnage Requirements 29
13.4 Pallet Requirement 30
13.5 Pack Requirement 30
13.6 Cleaning ,Repairs and Damages 33
13.7 Allocation 33
13.8 Shortages 34
13.9 Label Cardholders 34
14.0 Pillarization Requirement 34
14.1 Multiple / Common Item Packs 34
14.2 Mixed Load Pallets 35
14.3 Multiple Daily Pus Pallet Loading Guidelines 35
15.0 Packaging Qualification Procedure 35
15.1 Proposal 35
15.2 Proposal Review 36
15.3 Packaging Trial Process 36
15.4 Keys To Completing GM 1738i Packaging Approval & Data Form 38

EXHIBITS
Exhibit 1 : GM 1738i Packaging Approval & Data Form 34

Exhibit 2 : Completed Example of GM 1738i Packaging Approval & Data Form 35
Exhibit 3 : GM Packaging Approval Process 36
Exhibit 4 : Heavy Unit Load Label 36
Exhibit 5 : Modular Carton Sizes 37
Exhibit 6 : Modular Bulk Box Sizes 37
Exhibit 7A : GMTH Caster Standard 38
Exhibit 7B : GMTH Hook Standard 38
Exhibit 7C : GMTH Latch Standard 39
Exhibit 7D : GMTH Hammer Lock Standard 39
Exhibit 8 : GMTH Plastic Box and Rack Standard Size 40
Exhibit 9 : GC07 Global concept Container Buy-off sheet for Returnable container 41
Exhibit 10 : GC14 Global sample Container Buy-off sheet for Returnable container 42

REVISION LOG
DATE REQUESTER DESCRIPTION OF CHANGE

03/15/2007 Pornthep Makphanitwat, Implement GM 1738i
Aekkachai Horwatthakul , (Packaging approve and data from)
GMTh Global supply chain
10/03/2008 Aekkachai Horwatthakul, Implement GM 1738i

Anuthep Yimsing, (Packaging approve and data from)
GMTh Global Supply Chain
10/21/2014 Paitoon Onlamai Revise GM Package standard
Tepnakhon Maikami
Samruai Samran
GENERAL MOTORS (THAILAND) LIMITED

Supply Chain –Packaging
Passenger line part

Tepnakhon Maikami Ext: 3038
Truck line part

Samruai Samran Ext: 7054
Support Team
Paitoon Onalami Ext: 7478
Pailin Yongsiri Ext: 7143
Eastern Seaboard Industrial Estate 111/1 Moo 4,T.Pluakdaeng

A.Pluakdaeng, Rayong 21140, Thailand
Tel : (6638) 954999
Fax : (6638) 954995
E-mail : tepnakhon.maikami@gm.com
E-mail : samruai.samran@gm.com
E-mail : paitoon.onlamai@gm.com
E-mail : pailin.yongsiri@gm.com

PLEASE READ THE COMPLETE DETAILS IN GM 1738G
QUICK REFERENCE INFORMATION – EXPENDABLE PACKAGING
SUBMIT 1738i
SELECT BOX SIZE FORM GM APPROVAL
( MUST BE HSC 4.0 ) ( WEEK -80 TO WEEK -52
FROM SORP 2.4.4 )
YES DEVIATIONS NO
P
R CHOOSE 1 OF 12 PLASTIC BAGS (8.1) STYROFOAM (EPS)
HSC CARTONS (4.0) (8.1.2)
I RECYCLABLE FOAM SHEETS (8.1.2)
FOAM GLUED TO
M MATERIALS CORRUGATE (8.1.2)
PLASTIC WRAP (8.1)
A SAME STD PACK FOR
EACH BOX (3.1.2.2) UNRECYCLABLE
R WAX COATED KRAFT
MATERIALS (8.1)
PART QUALITY (4.0) PAPER (8.1.2)
Y
S
E TESTED STRENGTH TO
STACK FOUR (4) HIGH
WOOD SUPPORTS
(7.1.8)
WOOD CRATES/
COMPOSITES (9.0)
C AND/OR 2200MM MINIMIZE NAILS &
HIGH (2.1.9, 7.1.1)
O STAPLES FOR BULK METAL
DESIGN WITH BEST BANDING/HOOKS
N USE OF SPACE (3.0)
WIDE CROWN OR HINGES (8.3)
STAPLES (7.1.8)
D PLASTIC BANDING
ANY DEVIATIONS SHARP EDGES
A (8.3)
RECYCLABLE TO STANDARD
R MATERIALS (8.1) PACKAGING (2.3)
Y
P
1.INTRODUCTION
(4.0)
1140x980x127mm
PROTRUDING
A ISPM CERT. (Solid
OR SHARP
OBJECTS
L Wood) (2.1.13) HALF PALLET:
PLYWOOD, PARTICLE
L BOARD, LAMINATE
570x980x127mm
(7.1.1)
GMTH- Revision 6: Oct 2014 PageMETAL
5 of 42(5.0)
E (5.1.4)
WOOD >220 KG (5.1.4)

T
S
The purpose of this manual is to inform our supply base of GMTh specific guidelines required
to achieve optimum part quality while maintaining Lean Manufacturing efficiency within the
entire logistics and manufacturing process. Corporate wide benefits achieved are :
A) Reduced inventories to support Lean Manufacturing.

B) Improved ergonomics and work cell design efficiency.
C) Minimizing overall costs.
The supplier is responsible for maintaining part quality standards within the GMTH
determined container type. The supplier must provide packaging that can protect the parts
through its methods of transportation and types of handling planned for its final destination and
intended point of use (end user).
The packaging costs must be included in all part quotations and must be clearly defined in the
piece price (but shown separately). Returnable packaging must be cost justified between cost of
expendable vs. cost of returnable containers, inbound and outbound freight, and handling costs
associated with using returnable. All pricing must be negotiated through GMTH Purchasing.
1.01 References:
Additional requirements within GM Supply Power are specified in the following documents
Global & Regional GM1700 “Supply Chain Requirements”
GM Shipping Parts Identification Label Standard: GM1724
Form 1738i Packaging Data and Approval for Expendable container:
o Form 1738i
Form GC07 & GC14 Global concept Container Buy-off sheet / Global Sample Container
Buy-off sheet for Returnable container
Various bulletins archived at GM Supply Power
2.GENERAL REQUIREMENTS
All suppliers are responsible for the design and development of packaging, unless
otherwise specified from GMTH. The suppliers must ensure that all parts arrive at GMTH in
satisfactory quality condition. Any damages due to packaging will be the responsibility of the
supplier, High percentage of container utilization
(More than 85 % of available container volume capacity should be filled by material)
2.1 Small lot Packaging

All suppliers must provide parts to the operator in a user-friendly package that facilitates
damage-free and economical handling during shipment, storage, delivery and the best
ergonomics. GMTh shall review parts presentation upon the operation’s needs (See in request for
change packaging) for the criteria can summarize 6 items.
2.1.1 Product quality is promoted by:

Minimizing dunnage and handling requirements.
Minimizing preparation time and disposal activities (e.g. removal of banding, wrapping,
and collecting, sorting).
Utilizing GM specified labels on opposite sides of the container.
Providing clean containers that protect part quality.

Support of container cleaning processes and label removal prior to shipment to GM
facilities. Suppliers are responsible for maintaining clean all returnable containers (either GMTh or Supplier
owned). This includes removing residue and/or dunnage as required and prior to usage. Returnable
containers must be cleaned of all one time shipment labels.
2.1.2 Containers (and dunnage) are right-sized to support the following:

a. Reductions of ergonomic stress by meeting ergonomic lifts and reach guidelines.
b. Workstation layout efficiency.
c. Part delivery frequency.
d. Minimized repacking operations.
e. Efficient transportation costs.
2.1.3 Fork truck usage is minimized through the use of hand held containers and dolly
exchange.
2.1.4 Standard pack quantities provide for frequent delivery.

a. Point of use inventory target is 2 hours for manually handled container.
b. Point of use inventory target is 4 hours or less for bulk containers.
2.1.5 Container contents should fill the container (no air)

a. Fasteners filled by weight or quantity.
2.1.6 Material is shipped in production containers for any plant build event.
Small, standard sized containers are preferred for line side use. Bulk (large pallet size)
containers are used where part size and weight precludes use in a hand tote delivery method. In
all cases, those containers can only be used after obtaining approval from GMTH packaging
department. GMTH encourages the use of mobile racks where possible. All mobile racks must
comply to GMTH standards regarding designs for stacking and necessary hitches for pulling racks
with mobile equipment.
2.2 Ergonomics guideline

All hand-held containers must comply with maximum weight of 15 KGS. For large pallet
sized containers weight is limited to container/pallet manufacturing specifications.
All returnable containers require supplier identification on container.
All returnable containers are required to have the supplier name permanently marked on each
container. For multiple shipping locations of same supplier, it is strongly advised that the supplier
identify the required return location on respective containers. This will ensure returnable
containers are directed to appropriate using location.
All packs must be cost effective. GMTH will also pay for all expendable packaging as a per
piece price cost. GMTH expects suppliers to propose returnable packaging if Supplier base on
local.
Supplier initiated packaging changes are not allowed without prior review from GMTH
Packaging Department. In the case of an emergency, Packaging must be notified prior to shipping
if there is a change in packaging (i.e. part quantity change, box size change). See GM 1738i
(Packaging approve and data from).

2.3 Shelf-life
Shelf life is proper storage conditions and important to products as relates to chemical
specification, environmental and temperature etc and all those involved in the handling process
should be awared of this. Shelf life of product may be defined as the time between the
production /packing of the product and point at which it becomes unacceptable under defined
environmental condition. For the manufacturing product this will include :
Product design (including specification of materials)

Specification and testing of ingredients and packaging materials.
Manufacturing processes
Transport , storage , and retail display
Storage at plant and consumption
Environmental impact
GMTh requests suppliers who provide the shelf life part or critical parts to plant to identify
the shelf life in packaging approval form and request for change packaging form. This requirement
is requested also into packaging labeling in order to communicate and visualize for plant
operation.
All shelf life material or part must be in line with FIFO in supplier plant storage and delivery
to GMTh with following FIFO process.
3. GENERAL REQUIREMENTS FOR EXPENDABLE PACKAGING
3.1 3.1 Supplier* Responsibility

The supplier is the overall responsibility to ensure the component quality and packaging from
the shipping location to the domestic/regional shipping point (DUNS) where ownership is
transferred to GM. All packaging must be developed in accordance to the GMTh Packaging
manual, terms, conditions, regulatory requirements of the receiving warehouse location.
3.1.1 Per the GMTh GSC Packaging Requirement as following applies:

Suppliers will provide and use expendable packaging for intercontinental shipment of
production parts / components. Unless otherwise directed by General Motors, GMTH
does not provide returnable containers for the intercontinental movement/storage of parts.
Supplier shall maintain responsibility for the design and implementation of any
expendable packaging required for shipping parts to GM Receiving Locations. This includes
expendable dunnage to protect the part if required.
The Supplier will design expendable packaging for shipment of material. Refer to the
GMTh expendable Packaging requirements for Production Parts for the Intercontinental
Expendable Container sizes.
Supplier is responsible for providing expendable containers from their intercontinental
manufacturing location to the GMTh Receiving Location.
If GM determines that Supplier’s warehouse will be utilized as the domestic/regional
shipping point (Duns), Supplier will responsible for the packaging material (expendable or
returnable), intercontinental logistics, and repacking of parts into

small lot returnable containers. In this case, Supplier shall be responsible for all re-packaging
cost.
3.1.2 The supplier must identify a designated individual to handle all packaging
responsibilities, inquiries, improvements, and problem resolution. The individual’s
name and telephone number should be documented on the Form# GM 1738i Global
packaging Buy-off and Data Sheet.
3.1.3 Design, plan and maintain sufficient supply of suitable expendable containers for
normal shipments, premium shipments, production run-ahead programs, service
orders, etc.
3.1.4 Suppliers are required to work with the GMTh Packaging Engineer to optimize
carton size, density, and dunnage (if required) to minimize repacking activities into
returnable containers at the destination GMTh Warehouse location.
3.1.5 Suppliers are required to submit an initial packaging plan proposal (Form# 1738i Global
Packaging Buy-off and Data Sheet – see section Exhibit 1 & 2) for each part / destination
by e-mail to the GM Regional / Business Unit Contact / Approver for approval (Form
1738i Regional / Business Unit Contact / Approver List). This must be submitted week -
80 to week -52 from Start of Regular Production (SORP.). Suppliers are responsible to get
Concept Packaging ( GM 1738i ) approval before week -45 and Physical Verification
approval before week -24 from SORP for Expendable.
See Exhibit 3 for the Packaging Approval Process.
3.1.6 Suppliers must deliver production parts in the approved GM Intercontinental

expendable carton size (See section 6.0) and standard pack quantity as approved by
the Packaging Engineer. These modular expendable carton sizes are designed to
maximize cube for intercontinental transport.
3.1.7 Suppliers must properly load expendable containers to ensure production part
quality is not compromised and to comply with any other shipping instructions
from the GMTh Packaging Engineer. Any deviation in container type must be pre-
approved by the GMTh Packaging Engineer. Failure to do so will result in the
issuance of a Problem Reporting Resolution (PR/R).
3.1.8 Suppliers must load all intercontinental parts / components into transportation
equipment (Sea containers) at a minimum of 85% cube utilization to reduce overall
GMTh logistic cost. The exception to this requirement is when the weight capacity
of the transport equipment is maximized before 85% minimum cube utilization.
Failure to do so will result in the issuance of a Problem Reporting Resolution (PR/R.)
3.1.9 Expendable containers must be validated by the production part supplier prior to
first shipments to the customer plant, with documentation that proves validation
tests have passed. This test shall include shock & vibration test to assure part
/component quality.
3.1.10 All material must be palletized to permit handling with industrial fork trucks when
sufficient part quantities are to be shipped.

3.1.11 Ensure a full level modular unit load is established for all intercontinental
shipment of parts / components. All four corners of the pallet must be supported
with product and/or packaging material to create a modular stacking unit load.
Pyramid pallet loads are strictly prohibited.
3.1.12 Expendable unit load packs shall have sufficient strength to stack four unit loads
high and/or to a height of 2280 mm (whichever is greater) in a international
transport sea container under dynamic weight loading.
3.1.13 Suppliers must pack, label and ship in compliance with the requirements of
common carriers, and follow all applicable “Hazardous Materials Transportation
Regulations” including UN Hazard Communication Standards. Federal Motor
Vehicle Safety Standards (FMVSS) or On-Board Diagnostics (OBD) designated
parts may require special packaging and approval.
3.1.14 Use corrosion inhibiting materials (VCI or similar products) where there is
potential of corrosion to the part/component for intercontinental shipping of
production material to be included in the piece price and/or suppliers expense.
Suppliers must conduct testing to ensure that the corrosion protection applied will deliver
good quality parts to the GM Receiving Location.
3.1.15 Maximum weight of any unit load over 300 kilograms (660 pounds) requires
identification label on a minimum of 2 sides on the unit load, a minimum of 150mm
x 100 mm (6” x 4”) in size, and “Red” in color. See Exhibit #4 in references for sample
label.
3.1.16 Import / Quarantine Requirements for Wood Packaging Material (including

pallets/ dunnage/braces)
3.1.17 Current ISPM 15 Regulations requires all wood packaging material (including
dunnage) that is utilized for intercontinental movement of parts / components
MUST comply with the ISPM 15 (International Standards for Phytosanitary
Measures - Guidelines for Regulating Wood Packaging Material in International
Trade).
3.1.18 It is the supplier’s responsibility to conform to the requirements. Proof of this

treatment will be marked accordingly on the outside of the packaging material.
Please visit web site: www.ippc.int. Suppliers that fail to comply with this
requirement are liable for any and all costs and fines incurred by General Motors.
These costs could include additional costs to clear the material for import (such as
fines, fumigation costs, re-inspections costs, etc.) and costs needed to cover
production requirements during any delay to get material cleared through customs
(such as expediting costs for additional material to maintain production).
3.1.19 Suppliers must label containers in accordance with the GM Shipping Parts Identification
Label Standard (GM1724) available in GM Supply Power.

3.2 GM Regional / Business Unit Contact / Approver Responsibility
3.2.1 The GM Regional / Business Unit Contact / Approver is required to approve the initial packaging
plan proposal for each part / destination submitted by the Supplier. (Form# 1738i Global
Packaging Buy-off and Data Sheet – see section 2.1.2 and Exhibit 1&2)
3.2.2 GM Regional / Business Unit Contact / Approver must work with the Supplier to optimize carton
size, density, and dunnage (if required) to minimize repacking activities into returnable containers
at the destination GM Receiving Location.
3.2.3 Final expendable packaging approval will be made after successful production shipments have
been made.
4. COMPLIANCE STATEMENTS
All suppliers must comply with the Packaging Procedure Manual. Adherence to these
requirements is mandatory. Non-compliance will result in a Problem Reporting and Resolution
(PRR) issued by GMTH Packaging. Any charges for repackaging and / or disposal will be billed
back to the supplier shipping location. GMTH also reserves the right to demand supplier presence
on site GMTH to correct any quality problems related to packaging. Any continuous violation or
reoccurring problem will be referred to GMTH Purchasing for further action, and Packaging
compliance will be an important measure used by GMTH for ongoing supplier evaluation.
4.1. Continuous Improvement
4.1.1. GM strives for continuous improvement from a packaging and supply chain perspective.
Requests for changes of approved packaging may be made by the supplier, the receiving
warehouse, the GMTh Packaging Engineer, and/or GM. Suppliers are required to have a
single packaging point of contact to respond quickly to any change requests.Suppliers are
encouraged to provide continuous improvement opportunities regarding packaging and
to use the supplier suggestion process (located in GM Supply Power) to get credit for
continuous improvement.
4.1.2. Suppliers are encouraged to provide continuous improvement opportunities regarding

packaging and to use the supplier suggestion process (located in GM Supply Power) to get
credit for continuous improvement.
4.1.3. Suppliers may need to submit change request documentation to the GMTh Packaging
Engineer and/or packaging cost changes to the GM Global Purchasing Buyer.
4.2 Packaging Costs
4.2.1 All expendable packaging cost for the part / component must be identified and
integrated into the commodity piece price GM Global Purchasing quote package. Your GM Global
Purchasing Buyer will negotiate the packaging cost during the contract establishment phase.
4.2.2 Price increases will not be granted for increased cost to correct defective and/or non-
conforming packaging including supplier-provided dunnage, containers, securement, pallets, etc.

4.2.3 No price increases will be granted to suppliers who fail to comply with the Global
GM1738 Packaging Guidelines and Specifications.
5. EXPENDABLE CONTAINER SHIPPING SYSTEMS
An expendable shipping system is comprised of contained components having a life

expectancy of only one trip from supplier to customer. The Supplier shall maintain
responsibility for the design and implementation of any expendable packaging.
Expendable containers must be validated by the production part supplier prior to first
shipments to the GM Designated Warehouse, with documentation that proves validation tests
have passed shock & vibration tests to assure quality. Some Shipping & Receiving Locations
may require extensive use of specific sizes or designs. Consult your GMTh Packaging
Engineer for additional information.
REQUIREMENTS FOR CHOOSING THE RIGHT EXPENDABLE CONTAINER
The supplier is responsible for overall expendable container size selection, standard pack
determination, and dunnage development (if required) for intercontinental parts /
components supplied to GM Packaging Engineer. The following are the guidelines for
choosing the right expendable container:
5.1 Suppliers are required to develop an initial expendable packaging proposal

utilizing the Form# 1738 Global packaging Buy-off and Data Sheet – see section 3.1.3 and
Exhibit #1 & #2.
5.2 With development of the packaging proposal, the supplier must use the following
guidelines:
Packaging must maintain part quality during shipping and handling.

The parts must be oriented to minimize unpacking effort and the packaging must allow
unpacking without injury to the operator or damage to the parts.
Suppliers are required to work with the GMTh Packaging Engineer to optimize carton
size, density, and dunnage (if required) to minimize repacking activities into returnable
containers at the GM Designated Warehouse location.
5.3 Development of Carton Size and Standard Pack quantity:
5.3.1 Carton Size : Start with the smallest intercontinental carton size that the part fits
to ensure part quality and that the carton is completely filled.
Utilize an intercontinental carton size that will minimize repacking activities at the
destination warehouse with an easy transfer of expendable dunnage (if required.)
Ensure the expendable container has been filled with a consistent standard pack
quantity and used in every shipment of this part.

Adjustments to the smallest carton size to a larger size may be proposed to
accommodate the optimized density and proposal can be made to the GMTh Packaging
Engineer.
5.3.2 Standard Pack: Establish one standard quantity per container.

For each part for the receiving warehouse location, ensure the standard pack will
maximize carton cube utilization and minimize intercontinental freight cost.
Supplier must collaborate with the GMTh Packaging Engineer in determining the
optimum standard quantity per container and submit as a part of the packaging proposal.
As a general guideline for material delivered line-side at the assembly center, the
number of pieces in a standard pack should hold 2 – 4 hour’s usage with the maximum of one
shift usage. Due to part size, weight and usage, the guideline may need to be adjusted, but
should not exceed one full shift.
Adjustments to increase the standard pack density may be proposed to maximize cube
utilization, and can be made to the GMTh Packaging Engineer.
5.3.3 Containers used must be modular to the GM approved modular standard

intercontinental pallet size:
Standard pallet size for International parts. Must follow 1140mm x 980mm +0, -
6.33mm (45”x 38.5” +0,-1/4”) shipping footprint and reflect edge allowance of approximately
12.7 mm (1/2 inch.)
5.3.4 Cartons should not be over the edge of the pallet.
5.3.5 Bulk containers (modular bulk boxes, etc.) are used when manually handled
containers cannot accommodate part size or weight restrictions.
5.3.6 Choose a GM Modular Carton, using expendable dunnage if required (See section
6.0). The use of interior dunnage is discouraged, but when deemed necessary, the design and
procurement of the expendable internal dunnage is the responsibility of the supplier. The
financial impact of dunnage must be identified in the quote package as well.
5.3.7 When part size will not permit the use of GM Modular Standard Carton, utilize
the GM Modular Bulk Box or size the package length to the part length while maintaining the
package width at 1140mm (2 wide in a Sea Container) to 2280 mm (1 wide in a Sea Container.)
See section 9.0 modular bulk boxes.
5.3.8 Ensure a full level modular unit load is established for all intercontinental
shipment of material. All four corners of the pallet must be supported with product and/or
packaging material to create a modular stacking unit load.
5.3.9 Use corrosion inhibiting materials (VCI products) where there is potential of
corrosion to the part / component for intercontinental shipping.
5.3.10 Suppliers are required to submit the initial packaging plan proposal (Form#1738
Global packaging Buy-off and Data Sheet–see section 3.1.3 and Exhibit#1 & #2)

6. GM GLOBAL INTERCONTINENTAL EXPENDABLE CARTON SIZE AND

CONSTRUCTION
See below GM ISO-Modular Carton Specifications for use with the Intercontinental
Standard Pallet Size as described in Section 5.0: ** (Reference only)
ISO Modular Carton Sizes:

Metric (mm) Carton Specification Max WT. Max WT.
CARTON Outside DIM BOX Min Burst Puncture Limit Limit
NUMBER GME Std. NA Std. AP Std. GMB Std. L W D TYPE Comp (kg) Strength (kPa) Resist (J) (Lbs) (KG)
20C6 KLT 3215 Not Standard Acceptable KLT 3215 285 185 160 HSC 208 1320 6 33 15
9C5 Not Standard SC151208 Acceptable Not Standard 370 320 195 HSC 294 1320 6 33 15
5C4 KLT 6429 SC241510 Acceptable KLT 6429 560 365 240 HSC 301 1320 6 33 15
4C4 Not Standard SC242311 Acceptable Not Standard 560 480 240 HSC 737 2470 12.8 33 15
HSC = Half slotted carton with lid
Important Note: All ISO carton sizes require the use of the 980 Modular Intercontinental Shipping Pallet (1140mm x 980 mm)
Approved Carton ONLY Modular Pallets
CARTON Metric (mm)
PALLET Outside DIM
NUMBER L W D
980 STD 1140 980 127
NOTE: Pallets can be wood, plastic & paper corrugate. If
pallets are wood, then they must meet current International
Plant Protection Convention (IPPC) guidelines for heat
treated or fumigated with methyl bromide and identified
accordingly.
HSC RSC
6.1 When determining carton size and construction, use only the GM approved
intercontinental expendable packaging sizes. Cartons/containers are to be designed
to be modular to the standard size shipping pallet. Cartons must not overhang the
pallet.
6.2 Half Slotted Container (HSC’s) with a removable lid is the approved GM design. The use of
Regular Slotted Cartons (RSC’s) is strictly prohibited (exception: NA Industry AIAG standard
fastener cartons that have “rip-away” lid removal.) One common cover over each full layer of
HSC’s on a pallet is the preferred method; although in some cases, (low volume requirements)
e.g., covers may be required for each individual carton.
HSC’s use less corrugated fiberboard, and reduce packing and unpacking labor as well as
reducing personal injury and part damage from the use of box knives, etc. The use of uncovered
(uncapped) HSC, unflanged tubes with unsecured bottom caps, and design style (custom made)
containers are not acceptable.

6.3 Hand access is required for expendable carton designs that provide carton handling
characteristics to meet GM corporate defined ergonomic standards and guidelines. Suppliers are
required to utilize the following specifications:
6.3.1.1 Two hand-access points (hand-holds) are required at opposite sides of the expendable
carton. These hand-holds are to be located on the “short-side” (width) of the carton.
6.3.1.2 The following cartons require hand-hold access:
CARTON
NUMBER
10C7
10C4
9C5
6C4
5C5
5C4
5C3
4C5
4C4
4C3
3C5
6.3.1.3 The hand-hold size should not exceed 105mm (4”) length and 40mm (1.5”) height.
40mm
Maximum
105mm
Maximum
6.3.1.4 Attached are examples of the GM preferred expendable carton hand-hold designs:
Perforated

Die-cut with barrier
6.4 Corrugated material used in shipping containers must have adequate strength to
withstand the test of usage. The parts and container must arrive in satisfactory
condition at the usage point. A minimum of 360 kg to 2978 kg compression and 275
pounds to 1100 pounds per square inch burst test is required for all corrugated
material.
6.5 The maximum weight of a manually handled container, including parts, must not
exceed 15 kilograms (33 pounds) unless otherwise directed by GM.
6.6 All containers must be constructed with an outside tab style manufacturer’s joint. A
stitched manufacturer’s joint is recommended, and will be required if a glued or
other type joint proves inadequate.
6.7 All containers and multi-wall tubes must have a box maker’s certificate visible on the assembled
container, and displaying edge crush, bursting or puncture test.
7. GLOBAL INTERCONTINENTAL 980 STANDARD PALLET SIZE AND

CONSTRUCTION
Suppliers are required to use the approved intercontinental standard pallet size. They
are designed to integrate with the intercontinental carton sizes to make a modular unitized
load and maximize cube utilization.
This section includes both wooden and corrugate constructed pallets for shipment of
intercontinental parts and components.
7.1 The Modular Intercontinental Shipping Pallet footprints is Length Width

Tolerance
1140mm (45 Inches) x 980mm (38.5 Inches) + 0 /- 6.35mm (1/4 inch”)
Alternate dimensions are not acceptable.

7.2 Pallet dimensions are stated as follows:
(Pallet length) x (Pallet width) x (Pallet height)
Pallet length: the length of the stringer.

Pallet width: the length of the deck boards.
Pallet height: the vertical distance from the floor to the top of the deck.
Thus, a 1140mm x 980mm x 127mm pallet has 1140mm stringers, 980 mm deck board, and
the top of the deck is 127 mm above the floor.
NOTE: For a four-way entry pallet, openings are required for all four sides of the pallet.
(By contrast, box and corrugated container manufacturers’ standard practice is to always state
the larger dimensions first.)

7.3 Corrugated Pallets - For pallet load weights under 220 Kilograms (500 pounds,)
corrugated fiberboard pallets are recommended.
1) Structural members of the pallet should be compatible with the carton by supporting the
edge and corners.
2) A solid corrugated deck is desired.
If paper fiber cores are used for load-bearing members, use no more than four with a
maximum thickness of 6.35mm (¼ inch). Recycle ability of pallet (100% corrugated preferred)
is required. Identification of manufacturer and/or pallet size must be printed on the pallet
runner.
7.4 Wood Pallets - The use of wood pallets should be restricted to pack/load weights
exceeding 220 Kilograms (500 pounds.) The use of composite wood products
(i.e.: plywood, laminate, particle board) is encouraged to reduce the consumption of virgin
wood packaging materials, overall cost, and compliance with ISPM 15 guidelines.
Non-reversible, four-way entry stringer construction wood pallets, with 95mm (3.5 inch)
minimum primary opening height are required, except where the gross (loaded) pallet weight
is less than 220 kilograms (500 pounds.) Corrugate pallets are desired for usage when the
overall gross weight of the pallet is less than 220 kilograms.
8. LOADING OF CARTONS TO PALLETS:
By utilizing the GM Intercontinental expendable cartons and modular pallet, mixed unit loads
of different carton sizes and / or part numbers is permitted.
8.1 Properly load the modular pallet to create a level unit load with proper alignment of the
cartons. Use of additional packaging and/or empty box (to level the unit load) is permitted.
8.2 Do not allow the cartons to overhang the modular pallet.
8.3 Modular unit load height must not exceed 1100 mm / 43.3 inches (including pallet)
standard height sea container, to enable stacking. Use of extended height (high-cube) sea
container and expendable packaging deviations must be approved by the GMTh packaging
Engineer.
8.4 Modular pallet bases must meet all specifications in section 6.0.
8.5 Suppliers must label containers in accordance with the GM Shipping Parts Identification Label
Standard (GM1724) available in GM Supply Power.
8.6 Ensure all cartons within the unit load are properly secured as detailed in section 11.
8.7 Properly secure the unit load to the pallet as detailed in section 10.3
8.8 Refer to the attached for proper carton load and orientation relative to the standard
GM 1140(1140mm x 980mm) modular pallet:
9. MODULAR BULK BOXES SIZE AND CONSTRUCTION
Modular Bulk Box cartons are corrugated flanged cartons fastened to a pallet and is
generally used for bulk shipments of intercontinental parts / components.

9.1 See below ISO Modular Bulk Box and approved Bulk Pallet Specifications:
ISO Modular Bulk Box Sizes

Metric (mm) Carton Specification Max WT. Max WT.
BULK BOX Outside DIM* BOX Min Burst Puncture Limit Limit
NUMBER GME Std. NA Std. AP Std. GMB Std. L W D* TYPE Comp (kg) Strength (kPa) Resist (J) (Lbs) (KG)
B570A V195 Not Standard Acceptable 1/2H10F/T 980 570 240 HSC 1200 1100 14.2 660 300
B570B V154 Not Standard Acceptable 1/2H20F/T 980 570 440 HSC 1200 1100 14.2 660 300
B980A V149 Not Standard Acceptable CP484025 1140 980 430 HSC 1200 1100 14.2 660 300
B980B V196 28849 Acceptable CP484034 1140 980 620 HSC 1200 1100 14.2 660 300
B1140A Not Standard KC484525 Acceptable Not Standard 1140 1140 510 HSC 1200 1100 14.2 660 300
B1140B Not Standard KC484534 Acceptable Not Standard 1140 1140 970 HSC 1200 1100 14.2 660 300
B1300A Not Standard 17113 Acceptable Not Standard 1320 1140 510 HSC 1200 1100 14.2 660 300
B1300B Not Standard 17112 Acceptable Not Standard 1320 1140 970 HSC 1200 1100 14.2 660 300
B1490A Not Standard Acceptable Acceptable Not Standard 1490 1140 510 HSC 1200 1100 14.2 660 300
B1490B V203 Acceptable Acceptable Not Standard 1490 1140 995 HSC 1200 1100 14.2 660 300
B1700A Acceptable Acceptable Acceptable C704825 1700 1140 510 HSC 1200 1100 14.2 660 300
B1700B Acceptable Acceptable Acceptable C704834 1700 1140 970 HSC 1200 1100 14.2 660 300
B1980A Acceptable Acceptable Acceptable Not Standard 1980 1140 510 HSC 1200 1100 14.2 660 300
B1980B Acceptable Acceptable Acceptable Not Standard 1980 1140 970 HSC 1200 1100 14.2 660 300
B2280A Acceptable Acceptable Acceptable C4287T / F 2280 1140 510 HSC 1200 1100 14.2 660 300
B2280B Acceptable Acceptable Acceptable Acceptable 2280 1140 970 HSC 1200 1100 14.2 660 300
* = Does NOT Include pallet height in overall container height dimension
HSC = Half slotted carton with lid
Important Notes: 1. For Pallet Loads Greater Than 300 KG, the use of reinforcements, additional flutes, and/or stronger flutes are required
2. Maximum stacking height is restricted to 4 pallets high
3. All ISO Modular Box sizes require the use of the approved pallet sizes
Approved Bulk ONLY Modular Pallets

BULK Metric (mm)
PALLET Outside DIM
NUMBER L W D
570 570 980 127
980 1140 980 127
1140 1140 1140 127
1320 1320 1140 127
1490 1490 1140 127
1700 1700 1140 127
1980 1980 1140 127
2280 2280 1140 127
NOTE: Pallets can be wood, plastic & paper corrugate. If
pallets are wood, then they must meet current International
Plant Protection Convention (IPPC) guidelines for heat
treated or fumigated with methyl bromide and identified
accordingly.
HSC RSC
9.2 GM Modular Bulk Boxes are generally used for parts that are over 1200mm (47
inches) in size.
9.3 All modular bulk boxes must utilize the established intercontinental expendable
container sizes. Modular bulk boxes are designed to be modular to optimize cube of the
standard size intercontinental sea container. See table above for the approved modular bulk
boxes footprints.

9.4 See below for GM Modular Bulk Box illustrated below:
9.5 All modular bulk boxes must not exceed 1100 millimeters (43.3 inches) in overall
height unless approved by the GMTh Packaging Engineer.
9.6 Corrugated material used in shipping containers must have adequate strength to
withstand the test of usage. The parts and container must arrive in satisfactory condition at
the usage point. A minimum of 2962 kg to 3061 kg compression and 1100 pounds per square
inch burst test is required for bulk boxes.
9.7 All modular bulk boxes must be constructed with a “Breakaway” feature or be
easily disassembled at the receiving location for recycling.
9.8 Wood Corner Supports - All corrugated cartons are to be recycled after use. Any
contaminant such as wood that is fastened to the corrugated material requires intensive and
costly labor to separate.
Alternatives are to:

1.Eliminate the use of wooden supports where possible. The GM approved carton
strength may be currently acceptable. Or increase the corrugated test strength of the container
to a double or triple wall thickness.
2. Replace the wood with formed paper corner structures, or corrugated supports. These
paper corners may be stapled in place, since they can be recycled with the sleeve. The use of “angle
board” with a white clay coating and non-water soluble adhesive is not allowed. The cross-sectional
area allows virtually no surface to support a load. As a last resort, wood may be used as a corner
support, but must NOT be stapled to the corrugated -sidewalls of the container. Other methods of
holding the wood in place must be used, allowing ease of wood removal. Corner “kick-ins” or
corrugated pockets will suffice.
10. DUNNAGE, CLOSURE, AND SECUREMENT
10.1 INTERNAL DUNNAGE
Dunnage should be discouraged whenever possible and used only when part-to-part
contact must be eliminated to prevent damage in shipping and handling. Suppliers are
responsible for the design, performance, and procurement of all expendable dunnage.
Expendable internal dunnage is main stream, and must be included in the supplier’s quotation.
The internal dunnage should be designed for minimal set up, maximizing density,
loading and unloading labor, and allow for ease of recycling and/or disposal. The use of
partition or cell type dividers is generally preferred over individually wrapping parts, to
minimize labor. The use of dunnage constructed of combined and/or non-recyclable materials
(i.e., foam glued to corrugated) is difficult to separate and recycle, and is therefore discouraged
for use.
10.1.1 Use corrosion inhibiting materials (VCI products) where there is potential of
corrosion to the part / component for intercontinental shipping of production material.
10.1.2 Internal Dunnage Materials - The use of foam or foam sheeting as an expendable
material is discouraged. Currently, we have no economical solutions for recycling foam,
which causes the material to be land filled or returned to the suppliers at their expense. Foam
glued to corrugated and any other dissimilar materials bonded together, and expanded
polystyrene (EPS, or “Styrofoam”) are discouraged for use as expendable dunnage. Wax
coatings are discouraged for use, and foam sheeting is not desirable.
Alternatives are to:

1. Recycled materials such as die-cut corrugated or molded Kraft paper pulp.
2. Mechanical attachment of foam to corrugated or other dissimilar materials.
10.2 CARTON / CRATE CLOSURE
The general guidelines of the method in which containers must be sealed after being
filled are stated as follows.
10.2.1 Containers must be adequately sealed to ensure they do not open during shipping
or handling.
10.2.2 Removable lids are recommended for cartons and modular bulk boxes. A removable
lid to cover the entire layer of modular cartons may be utilized as an alternative for individual
carton removable lids.
10.2.3 Packaging materials containing asphalt, such as asphalt sealing tapes, must not be
used. Environmentally, paper type (repulpable) is preferred over plastic film tapes where
sealing performance is not compromised.

10.3 SECUREMENT - CONTAINER TO PALLET
All expendable containers shipped on pallets must be adequately secured to the pallets.
Multiple containers must be properly stacked on and secured to pallets. Plastic strapping and
plastic stretch wrap have been the acceptable method of securing cartons to a pallet. The
assembly plants are working to recycle all packaging materials, including strapping and
stretch wrap.
The following methods are to be used for securing cartons to a pallet:
10.3.1 Unitizing Adhesives - Use of a high shear/low tensile strength, quick release liquid
utilizing adhesives is the best environmental option. Use of this special adhesive requires no
strapping or stretch film to be collected, processed or recycled. Recycling of the carton is
unaffected. Unitizing adhesives require proper employee training and performance
monitoring by the supplier. The benefits of using this method are:
Wrap time eliminated

Equipment/floor space savings
Load integrity, appearance
Inspect/repack ease
Unit load increased. Nothing stretches/moves. Possibility for corrugated reduction
10.3.2 Plastic (Non-metallic) Strapping - A minimum of two bands lengthwise and two
bands widthwise must be used. Polyester strapping is recommended due to its strength and
recovery properties. Polyester strapping is recommended to be translucent green and
polypropylene strapping is recommended to be translucent clear. Non-metallic strapping
must be joined with a “friction seal”. Metal banding, clips or buckles are prohibited.
10.3.3 Stretch film - Stretch film must be linear low-density polyethylene (LLDPE) and clear
in color to maximize recycling potential. Polyvinyl chloride (PVC) film is not to be used.
11. ACCEPTABLE GLOBAL SHIPPING PRACTICES:
Only use approved GM intercontinental expendable packaging cartons, modular bulk

boxes, and pallets to the exact specification.

Acceptable Unacceptable
(Non-Standard Packaging)
Utilize removable lids for all parts / components that will be delivered directly into a GM
Europe / GM Latin America ONLY Assembly Center.
Design expendable dunnage to minimize repacking activities at GM Receiving

Warehouses.

Ensure the carton / modular bulk boxes density is maximized.
Ensure level unit loads for shipment. Use additional packaging material to level unit
and load when required.
Ensure expendable container specifications can meet minimum 2280 mm.

(89 inches) stacking requirements.
Acceptable

12. UNACCEPTABLE GLOBAL SHIPPING PRACTICES:
Pyramid packs are unacceptable. Packaging on pallet, use dummy boxes for complete level
of unit load.
Unacceptable Acceptable
(Not complete level of unit load) (Use dummy boxes for complete level)
Don’t use cartons/modular bulk boxes that are not an approved GM intercontinental size.
Unacceptable

“Do Not Stack” or “Stack Only Two High” labeling is unacceptable.
Unacceptable
Do not allow cartons to overhang pallets. Ensure they are properly stacked and secured.
Overhang!

13. RETURNABLE CONTAINER / RACK REQUIREMENTS
13.1 SUPPLIER REQUIREMENTS
GMTH requires all suppliers to submit a returnable packaging proposal for each part, suitable,
taking into consideration the following factors:
Initial Investment
transportation costs
standardization
Returnable container in loop size (sufficient container quantity)
handling issues-ergonomics
cube utilization
internal constraints
product protection
Returnable packaging must be considered case by case. In a limited number of cases,

returnable packaging will not be feasible if the above factors do not support.
Unless otherwise noted, suppliers have the responsibility of design, development, testing and
maintenance of returnable packaging. The supplier is required to submit all returnable
packaging proposals, including costs, to their assigned GMTH Packaging Engineer. The
GMTH Packaging Engineer will review the proposal for feasibility within the GMTH system.
Suppliers are required to submit an initial packaging plan proposal (Form# 1738i Global Packaging Buy-
off and Data Sheet – see Exhibit 1 & 2) for each part destination by e-mail to the GM Regional / Business
Unit Contact / Approver for approval (Form 1738i Regional / Business Unit Contact / Approver List). This
must be submitted week -80 to week -52 from Start of Regular Production (SORP.). The suppliers are
responsible to get Concept packaging ( GC07 ) approval before week -45 and Sample buy off approval (GC14)
from packaging engineer before week -35 (Refer Example 13).
13.2 RETURNABLE SYSTEMS
Stack and Nest Container System

GMTH recommend use of stack and nest containers. The containers provide a high return
ratio. Compatible pallets are recommended, preferably vacuum-formed pallets due to its light
weight property.
Sleeve Packs
There are various pallet, lid and sleeve combination packs available. Footprints must comply
with standard pallet footprints (see section 6.4) .Any non-standard footprint needs prior
approval from GMTH Packaging Engineer. There are no standard container sleeve heights,
but the sleeve cannot exceed 1270 mm. in height when assembled. This allows for double
stacking in transit. Preferred sleeve material is triple-wall corrugate or double-wall plastic
corrugate. Also the sleeve must have the ability of locking onto the pallets. Dunnage must
have ability to collapse or be stacked in empty containers upon return to supplier.
13.3 DUNNAGE REQUIREMENTS

All dunnage must be designed to accommodate the container utilized and approved by
GMTH. Space utilization should be maximized and returnable dunnage is preferable
requirement.
13.4 PALLET REQUIREMENTS
GMTH requires use returnable pallets that are compatible for the returnable container system
in which it contains. Most returnable containers have compatible pallets. All standard
returnable will use a 1100 x 1100 x 127 mm. pallet specifically designed for that container
system. Returnable pallets will be used to increased strength factors and reduce costs. For
environmental factors, a reusable pallet is required pallet type. Please contact your GMTH
Packaging Engineer if considering the use of returnable pallets with expendable containers.
Size:
GMTH standardizes pallet must be plastic size as follow 1100 x 1100 x 127 mm.
Any size used that is not standard (not shown above) must be confirmed with the GMTH
Packaging Engineer for approval.
Type:
All pallets must have four (4) way entries, compatible for either forklift or pallet lifts. GMTH
requires use of either vacuum formed, structural foam or molded plastic pallets. The pallet
strength must comply with the required strength due to the weight that is
contained. Do not use pallets that cannot structurally contain the weight that is stacked onto
it.
13.5 RACK REQUIREMENTS
GMTh request supplier to produce footprint of rack following by GMTh Dolly standard and
these rack could not impact with operation, line side, ergonomics, material flow safety issue.
For the rack requirement must to protect and avoid any material damage between warehouses
to GMTh line side. Rack must protect the dust for part with appearance concerned.
13.6 CLEANING, REPAIRS AND DAMAGES
All suppliers are required to clean the containers/racks on a regular basis or as request.
Containers that arrive at GMTH with excessive dirt and debris are unacceptable.
If containers/racks are found in need of repairs, the supplier must tag the container and
ensure that repairs are made before re-using (Yellow Tag Process).
If there are containers/racks that are damaged beyond repair (they should be replaced by the
supplier) .The supplier is responsible for maintaining the agreed container bank.
13.7 ALLOCATION
CYCLE TIME FACTORS

- Days Inbound Freight - Days Outbound Freight
- Day GMTH Safety Stock - Day at Consolidation Center
- Day in Process - Day at Supplier
- Day empty - Total System Days Container Allocation
Any additional days of container are solely up to the supplier to order and purchase.
Container allocated bank may vary, depending on freight distance and shipping frequency.
This will be agreed on a case by case basis.
13.8 SHORTAGES
All packaging shortages must be reported to GMTH Packaging Engineer immediately. This
pack must have prior written approval from GMTH Packaging Engineer before shipment.
Expendable back up packaging is acceptable only if there is no alternative returnable
packaging. Expendable backup must have same or smaller than original size and same
quantity as returnable packaging.
13.9 LABEL CARDHOLDERS
GMTH requires 2 label Cardholders per returnable container/rack. The location of these
cardholders must be on short ends of container, unless otherwise specified. The holder must
be permanently affixed by rivets. Adhesives can be used only if it is not possible to rivet the
holders. The cardholders will be used for label placement at the supplier.
Any containers that arrive at the supplier with labels still in the cardholder must be
removed. This will prevent any part mixing at GMTH.GMTH will approve cardholders as
part of GMTH Packaging Approval Process.
13.20 PLASTIC BOXES REQUIREMENTS
GMTH requires use returnable plastic boxes that are compatible for the returnable container
system in which it contains. Suppliers can be chosen container standard size of plastic boxes
for design dunnage by contact with GMTh Packaging Engineer for suitable packaging with
part dimension. See Exhibit #12
14. PALLETIZATION REQUIREMENTS
14.1 MULTIPLE/COMMON ITEM PACKS
A multiple/common item pack contains a single (1) part number in multiple containers
stacked on a pallet. Only one (1) PuS order allowed per pallet. Each pack must include:
1. A master label (ref. shipping/parts identification label requirements manual), placed on top
banding so it can be removes upon arrival.
2. Two (2) labels per container, facing outward, on a pallet.
3. Proper banding techniques for each pallet.

14.2 MIXED LOAD PALLETS
A mixed load pallet contains multiple part numbers in containers stacked on a pallet. Only
one (1) PuS order allows per pallet. Each mixed load pallet must include;
One Mixed Load Label per pallet (ref. Shipping/parts Identification Label Requirements
manual)
Proper stretches wrap/banding techniques for each pallet.
14.3 MULTIPLE DAILY PuS PALLET LOADING GUIDELINES
Since GMTH will expect multiple daily PuS ordering, strict guidelines must be met to assure
correct shipping method to GMTH. The following guidelines were developed for better
understanding of pallet loading requirements:
Do not mix PuS orders on a pallet.
Arrange/group boxes on a pallet by GMTH store location, if possible.
With each PuS order, mixing part numbers is allowed on a pallet up to standard maximum
stacking height of 1100 mm. This allows double stacking in trailers. Do not exceed this
requirement without pre-approval from your respective GMTH Packaging Engineer. Parts
with different dock codes (PuS) cannot be on same pallet.
Arrange all boxes on a pallet so the labels are facing outward.
Each pallet with mixed part numbers must be labeled “MIXED PALLET “. The label lists
the quantity of boxes per pallet (ref. Shipping/Parts Identification Label Requirements
Manual. Refer and follow GM1724 Master Label type C guideline.
Each pallet requires a PuS label. The label specification is an 220 mm. x 140 mm paper
size.
15. PACKAGING QUALIFICATION PROCEDURE
All packaging must have prior approval before usage at GMTH. This means all packaging
alternatives, including quality concerns, handling issues, material used and timing must be
discussed between GMTH and the supplier.
GMTH will work jointly with the supplier to develop proper dunnage design. It is the
responsibility of the supplier to assure part protection in the container specified by GMTH.
15.1 PROPOSAL
GMTH requires GM 1738i Packaging Approval & Data Form (Exhibit 1 & 2) for Expendable
and GC07/GC14 Global concept Container Buy-off sheet / Global Sample Container Buy-off sheet for
Returnable to be filled out by supplier for the proposed pack of each part number. There are
two exceptions to which one form can be used for more than one part number. One exception
is where a group of parts are dissimilar only by color. The second exception is when parts are
very similar in shape and weight and use the same packaging. In both cases, all part numbers
must be included on the form or attached to the form. Supporting documentation is required
on returnable packaging proposals, including pictures/drawings of the proposed pack
methods.
NOTE: All cost information, including cost for container, dunnage, pallet and containment
method (banding, etc.) must be directed through GMTH Purchasing.
This form must be submitted as soon as the information is available. Unless otherwise noted,
the supplier must complete and return the form within agreed GMTH and supplier timetable.
It is the supplier’s responsibility to meet this deadline. If this date cannot be met, please contact
GMTH immediately and an extension can be provided. Please send GM 1738i Packaging
Approval & Data Form and GC07/GC14 Global concept Container Buy-off sheet / Global Sample
Container Buy-off sheet for Returnable, along with any supporting documentation, to your
respective GMTH Packaging Engineer by fax and by mail.
15.2 PROPOSAL REVIEW
GMTH will review the proposal internally. Then, a proposal review will be held between
GMTH and the supplier to address all concerns. This review will designate which method is
preferred by GMTH. If no packaging trial is necessary, an approval letter will be issued to the
support at this point.
15.3 PACKAGING TRIAL PROCESS
All expendable packaging that is either new or modified design, and all returnable packaging,
may require a packaging trial before implementation at GMTH. The following is the proper
procedure for all packaging trials. (refer Exhibit 3)
Packaging trial process for imported and local parts (refer Exhibit 3)
1. GMTH Purchasing commits nominated suppliers and confirms and report to GMTH
packaging Engineer.
2. Packaging Engineer submitted up to date nominated supplier information.
3. GMTH packaging will contact and introduce packaging guideline to supplier
4. Packaging Engineer will request current packaging or draft idea and also drawing of
packaging and sent GM 1738i Packaging Approval & Data Form for Expendable and
GC07/GC14 Global concept Container Buy-off sheet / Global Sample Container Buy-off sheet for
Returnable for Returnable unfilled by mail to supplier.
5. Suppliers get GMTH requirements
6. Complete GM 1738i Packaging Approval & Data Form for Expendable and GC07/GC14
Global concept Container Buy-off sheet / Global Sample Container Buy-off sheet for Returnable for
Returnable and send to GMTH.

7. GMTH team will evaluate, review and make recommendation then return it back to
supplier.
8. Supplier will modify as recommendation and return the corrected information in GM
1738i Packaging Approval & Data Form for Expendable and GC07/GC14 Global concept Container
Buy-off sheet / Global Sample Container Buy-off sheet for Returnable for Returnable to GMTH
packaging Engineer.
9. Review by GMTH team in case of Packaging Engineer, Manufacturing & Production team,
Logistics. In case not accept packaging Engineer will notify to supplier for correction as item
8.
10. Conclusion that it’s necessary to get prototype. When the design is acceptable, a prototype
sample may be requested. If not necessary, continue to item 14.
11. Supplier is responsible for developing prototype designs to submit for review at GMTH.
12. Send prototype to GMTH with GM 1738i Packaging Approval & Data Form for
Expendable and GC07/GC14 Global concept Container Buy-off sheet / Global Sample Container Buy-
off sheet for Returnable for Returnable to packaging Engineer
13. The prototype must be submitted to GMTH for evaluation and accepted before continuing
to the next step. If it does not accept, return back to item 11.
14. GMTH Agree prototype.
15. Packaging Engineer will distribute GM 1738i Packaging Approval & Data Form for
Expendable and GC07/GC14 Global concept Container Buy-off sheet / Global Sample Container Buy-
off sheet for Returnable for Returnable to supplier and Request master plan Mass Production.
16. Suppliers identify and setup & send master plan mass Production to Packaging specialist.
17. GMTH team considers details master plan mass production. If teams not agree, must
return back to item 16.
18. Agree master plan mass production and sign off.
19. Sent Approval master plan mass production to supplier.
15.4 KEYS TO COMPLETING GM 1738i Packaging Approval & Data Form
Step 1:
Fill in the Supplier Information section completely. Be sure to include Packaging Contact; the
person who will be handling the packaging design and development.
Step 2:
Fill in the date in the top left hand Section 1.
Step 3:
Section1: Fill in the information about Program & Part information .Be sore Part Description,
Part Number, Part Dimension, Number of part/Vehicle, Part weight, Packaging Cost / Part
Step 4:
Section2: Fill in or select data about Packaging Information. This includes all specifications for
the box/container and material using type for PKG and dunnage such as dimensions
(centimeters), weight (kg) and quantity. That includes secondary packaging (If any). Please
fill this section as completely as possible

Step 5:
Section3: Fill in or select data about shipping & Logistics. This data is used calculate Cube
Utilization
Step 6:
For illustrations section, use pictures or drawings of the box and the pallet load.
Step 7:
Please complete the above instruction for the GM 1738i Packaging Approval & Data Form and
sent this information with any other supporting documents to your respective GMTH
Packaging Engineer by E-mail.
Step 8:
In term of Approval, this field is internal approval by GMTH

Reference:
REFERENCES: Exhibit 1 GM Form# 1738i Global packaging Buy-off and Data Sheet:
GM1738I Packaging
approval V 4.01.xlsm

Exhibit 2 Completed Example of GM 1738i Packaging Approval & Data Form Buy-off and
DataSheet

Exhibit 3 GM Packaging Approval Process:
Packaging Approval Process

To Support Intercontinental Shipping of Parts / Components
Supplier Customer
Form 1738i
(Country of Origin) submitted by
(Intercontinental Receiving Location)
GM 1738 Packaging Approval & Data Form
Supplier Infor mation
e-mail to the
Compa ny Na me : D UNS#
Compa ny Addre ss:
Pkg Contact Person:
City:
Te l No.
Cou ntry Code :
Regional Contact
Email Address: Fa x No.
Issue Date: MM/DD /YY
Effective D ate: MM/DD /YY Packaging Type: NEW from week -80 to
Section 1: Part Information
1-1. P rogram Name( s)
1-3. P ar t Numbers
1-4. P ar t Des cription / Name
1 -2 . MVBn/s - SORP: -
week -52 from
1-5. S equencing Strategy
1-6. P ar t W eight (kg)
1-8. Dimens ions L x W x H (mm)
1-7. Number of Parts / V ehic le: Start Of Regular GM Regional
Section 2: Packaging Infor mation
Primary Carton (box) Secondary (unit shipping load) Production Approval To
2-1. P ac kaging Strategy (Exp vs. Ret)
2-2. Description (bag, box ty pe, pallet) - Code
2-3. Material Type
Expendable
(SORP) Packaging
Tier1 2-4. Tare Weight (kg - empty)
2-5. Loaded Weight ( kg)
2-6. Outside Dimens ions LxW xH (mm)
2-7. Dens ity - SPQ (# of Parts per)
Representative Send Production
Supplier 2-8. Maximum layers c an be stac ked
Material To
Approver List
2.9. S ame or Mixed Load
2-10. Dunnage & Desc ription
2-11. Compliant to GM 1738 Specification's
Section 3: Shipping & Logistiics
(Click Hyperlink) GM Assembly

Tier1 3-1. W arehouse Terms (in Country of us e)
3-3. Deliver y Mode (Milkrun, dedic ated, etc .)
3-2. GM Logis tic's A gent:
3.4. Port of Import:
Completes
3-5. GM Cons ignee ( Ship to Location)
3-7. IS O S ea Container Mode
3-9. Number of Ret. Containers A vailable
3-6. Ret. Container ID:
3.8. # P allets per mode:
3-10. Ret. P kg. Owner:
and/or
3-11. INCO Terms (FCA , E xWorks, DDP , etc.) 3-12. Named Plac e:
Form1738i
3-13. GM Assembly P lant(s ) us ing these parts.
3-15. Returnable Dimensions (Pri &Secondary)
Section 4: Special requirements

3-14. Returnable Dens ity:
Powertrain
Plant
4-1. Chemic al P rotection Requir ed (VCI, Oil) 4-2. Repac k Required:
Packaging 4-3. S pecial Stor age Req. (temp, Hum, etc.)
Section 5: Visual Re fere nces (Pictures)

5-1. Pa rt Onl y 5-2. Part + D unnag e + Primary 5 -3. Part + Primary + Secondary 5 -4. Lin e Si de / Returnab le Containe r
Approval & GM Regional Packaging

Data Sheet
Representative To Perform
Form 1738i Approval
5-5. Repackin g Instructi ons / Comments:
Section 6: Approval information

GM Safety
S upplier: Date: & Ergo: Date:
6-1 .
GM Pkg GM Mfg. &
Eng.:
Date: P rod.: Date:
Re-do Process Until Approval Is Acquired...

No Form 1738i
Approved?
Yes
Form 1738i is
placed into
database Packaging
Approval
Complete
Packaging plan approved, Completed
Form 1738i feedback provided to Tier1
Key:
* Note: Process is repeated until packaging approval is complete.
GM Warehouse Approval Flow
GM Plant Approval Flow
Feedback to Tier1
Exhibit 4 Heavy Unit Load Label
Load > 500 kg (1100 lbs)
Label must be 150mm x 100mm (6” x 4”) minimum in size.

Exhibit 5 Container Strategy:
CONTAINER STRATEGY
To Support Global Supply Chain
Supplier Customer
(Country of Origin) (Intercontinental)
E
Tier1
Supplier S
R GMPT
Eng/Trans GMPT
SP Plant Eng/Trans
Plant
R SP R CP
Repack Repack
R R Vehicle
(eg Allen) (eg Excel)
In CV Assy
Out CV
Key:
E= Expendable is supplier designed – cost is in piece price
R = Returnable is customer designed – funding is in the A/R
S= Supplier is responsible
SP= Supplier-Powertrain is responsible
CP= Customer-Powertrain is responsible
Container Strategy.ppt/pblood/10-28-05 CV= Customer-Vehicle is responsible
Exhibit 06 Road Weight Limits:

Country Country of Origin TEU / Gross Weight 20' TEU Gross 40' TEU Gross 20' Nett 40' Nett 40' Nett 45' Nett 20' TEU 40' TEU 40' TEU 45' TEU
Code Transport Limit (Cargo & Weight Weight Weight Weight Weight Weight Tare Tare Tare Tare
Type Container) (Tri-Axle) *** (Tri-Axle) *** (Std Height) (Std Height) (High Cube) (High Cube) Weight Weight Weight Weight
Std Height High Cube High Cube
AUST Victoria Inland Truck 26,050 kg 2,370 kg 3,910 kg 4,100 Kg 4,800 Kg

Sth Australia
AUST Truck TBA
Inland
BEL Belguim 20' 29,500 kg 27,130 kg
CAN Canada 20' 20,513 kg 21,348 kg 21,318 kg 18,143 kg 17,408 kg 17,218 kg 16,518 kg
EGY Egypt 20' 30,000 kg 32,000 kg 27,630 kg 28,090 kg 27,900 kg 27,200 kg
GER Germany 20' 26,500 kg 24,130 kg
IND India 20' 23,000 kg 29,000 kg 20,630 kg 25,090 kg 24,900 kg 24,200 kg
INDN Indonesia 20' 29,000 kg 26,630 kg
JAP Japan 20' 24,000 kg 30,000 kg 21,630 kg 26,090 kg 25,900 kg 25,200 kg
KOR Korea 20' 20,370 kg 26,910 kg 18,000 kg 23,000 kg 22,810 kg 22,110 kg
MEX Mexico 20' 20,513 kg 21,348 kg 21,318 kg 18,143 kg 17,408 kg 17,218 kg 16,518 kg
NET Netherlands 20' 30,000 kg 32,000 kg 27,630 kg 28,090 kg 27,900 kg 27,200 kg
SAF Sth Africa 20' 24,000 kg 21,630 kg
SPA Spain 20' 24,000 kg 21,630 kg
TAI Taiwan 20' 23,000 kg 29,000 kg 20,630 kg 25,090 kg 24,900 kg 24,200 kg
UK UK 20' 30,000 kg 27,630 kg
USA USA 20' 20,513 kg 21,348 kg 21,318 kg 18,143 kg 17,408 kg 17,218 kg 16,518 kg
SWE Sweden 20' 30,000 kg 27,630 kg
THA Thailand 20' 20,513 kg 21,348 kg 21,318 kg 18,143 kg 17,408 kg 17,218 kg 16,518 kg

Exhibit 7A GMTH Caster standard
Exhibit 7B GMTH Hook standard

Exhibit 7C GMTH Latch standard
Exhibit 7D GMTH Hammer Lock standards

Exhibit 8 GMTH Plastic Box and Rack Standard Size
Rack Standard Size
L W H
Code
7000 2200 2200
RA412 1725 2200 1100
RA413 1725 2200 725
RA812 860 2200 1100
RA422 1725 1100 1100
RA523 1390 1100 725
RA623 1150 1100 725
RA723 985 1100 725
RA822 860 1100 1100
RA924 770 1100 550
RA933 770 725 725

*** Exhibit 9 GC07 Global concept Container Buy-off sheet for Returnable container
Request Supplier fill in data for Technical review

Exhibit 10 GC14 Global Sample Container Buy-off sheet for Returnable container
GC53_07_14_91
V2.50 _ Format.xlsx

GM1738 GMTH - General - Req 2014

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GMTH PACKAGING REQUIREMENTS

FOR PRODUCTION PARTS

GENERAL MOTORS (THAILAND) LIMITED

GMTH- Revision 6: Oct 2014 Page 1 of 42

GMTH- Revision 6: Oct 2014 Page 2 of 42

Exhibit 1 : GM 1738i Packaging Approval & Data Form 34

GMTH- Revision 6: Oct 2014 Page 3 of 42

DATE REQUESTER DESCRIPTION OF CHANGE

10/03/2008 Aekkachai Horwatthakul, Implement GM 1738i

GENERAL MOTORS (THAILAND) LIMITED

Passenger line part

Truck line part

Eastern Seaboard Industrial Estate 111/1 Moo 4,T.Pluakdaeng

GMTH- Revision 6: Oct 2014 Page 4 of 42

PLEASE READ THE COMPLETE DETAILS IN GM 1738G

QUICK REFERENCE INFORMATION – EXPENDABLE PACKAGING

WOOD >220 KG (5.1.4)

A) Reduced inventories to support Lean Manufacturing.

2.1 Small lot Packaging

2.1.1 Product quality is promoted by:

GMTH- Revision 6: Oct 2014 Page 6 of 42

2.1.2 Containers (and dunnage) are right-sized to support the following:

2.1.4 Standard pack quantities provide for frequent delivery.

2.1.5 Container contents should fill the container (no air)

2.2 Ergonomics guideline

GMTH- Revision 6: Oct 2014 Page 7 of 42

Product design (including specification of materials)

3. GENERAL REQUIREMENTS FOR EXPENDABLE PACKAGING

3.1 3.1 Supplier* Responsibility

3.1.1 Per the GMTh GSC Packaging Requirement as following applies:

GMTH- Revision 6: Oct 2014 Page 8 of 42

3.1.6 Suppliers must deliver production parts in the approved GM Intercontinental

GMTH- Revision 6: Oct 2014 Page 9 of 42

3.1.16 Import / Quarantine Requirements for Wood Packaging Material (including

3.1.18 It is the supplier’s responsibility to conform to the requirements. Proof of this

GMTH- Revision 6: Oct 2014 Page 10 of 42

4.1. Continuous Improvement

4.1.2. Suppliers are encouraged to provide continuous improvement opportunities regarding

4.2 Packaging Costs

GMTH- Revision 6: Oct 2014 Page 11 of 42

5. EXPENDABLE CONTAINER SHIPPING SYSTEMS

An expendable shipping system is comprised of contained components having a life

REQUIREMENTS FOR CHOOSING THE RIGHT EXPENDABLE CONTAINER

5.1 Suppliers are required to develop an initial expendable packaging proposal

Packaging must maintain part quality during shipping and handling.

5.3 Development of Carton Size and Standard Pack quantity:

GMTH- Revision 6: Oct 2014 Page 12 of 42

5.3.2 Standard Pack: Establish one standard quantity per container.

5.3.3 Containers used must be modular to the GM approved modular standard

5.3.4 Cartons should not be over the edge of the pallet.

GMTH- Revision 6: Oct 2014 Page 13 of 42

6. GM GLOBAL INTERCONTINENTAL EXPENDABLE CARTON SIZE AND

ISO Modular Carton Sizes:

GMTH- Revision 6: Oct 2014 Page 14 of 42

GMTH- Revision 6: Oct 2014 Page 15 of 42

7. GLOBAL INTERCONTINENTAL 980 STANDARD PALLET SIZE AND

7.1 The Modular Intercontinental Shipping Pallet footprints is Length Width

1140mm (45 Inches) x 980mm (38.5 Inches) + 0 /- 6.35mm (1/4 inch”)

Alternate dimensions are not acceptable.

GMTH- Revision 6: Oct 2014 Page 16 of 42

7.2 Pallet dimensions are stated as follows:

(Pallet length) x (Pallet width) x (Pallet height)