Bleached Board Quality - gppackaging.com€¦ · ©2017 GeorgiaPacific Bleached Board LLC. Confidential and Proprietary Information. Do not distribute or copy without prior cons-

©2017 Georgia-Pacific Bleached Board LLC. Confidential and Proprietary Information. Do not distribute or copy without prior consent. All rights reserved. | 1

Bleached Board Quality

Warehouse Standards and Guidance ManualVersion 3


This material is the property of Georgia-Pacific Bleached Board LLC. The material contained herein represents substantial

creative effort and may include trade secrets, confidential information, and other proprietary concepts, techniques, ideas and

expressions. This material may not be reproduced, altered or transmitted in any form or by any means (including, without

limitation, electronic, mechanical, photocopying, or recording means) or in connection with any information storage or retrieval

system, and may not be used in any manner whatsoever, without the express written consent of Georgia-Pacific Bleached Board

LLC. All trademarks are owned or licensed to Georgia-Pacific Bleached Board LLC. Your possession of this material constitutes

your acceptance of these conditions. If you do not agree with these conditions, immediately return the material to Georgia-Pacific

Bleached Board LLC.

Confidentiality


• Section 1: Overview• Section 2: Inbounds, Inspections, and Damage Reporting• Section 3: Handling & Storage• Section 4: Rework & Repairs• Section 5: GMP, Housekeeping, and Self-Audits• Section 6: Vehicle Inspections• Section 7: GP BB Load Plans and Load Best Practices• Section 8: GP BB Audits and Evaluations

Table of Contents


Section 1: BLEACHED BOARD OVERVIEW

Overview covering the business vision, quality policy, what is Bleached Board and the general expectations of Warehouses


• Vision• Quality Policy• What is Bleached Board?• Expectations

Bleached Board Overview


Apply MBM® to create and maximize long-term value for our customers, Georgia-Pacific, and society. Utilize our advantaged capabilities across global Cartonboard segments to understand and satisfy our customers current and future needs better than our competition. Value creation will be measured by our safety and environmental performance, return on capital, growth, and competitive position.

Bleached Board Vision


Georgia-Pacific Bleached Board continually seeks to maximize long term value by implementing a Quality Management System that results in Customer Satisfaction as a competitive advantage now and in the future

Quality Policy


The material you handle goes into a wide variety of finished goods. When people think of bleached board, they usually think of Solid Bleached Sulfate (SBS). SBS is a 100% virgin fiber paperboard grade made of bleached chemical pulp. At GP Bleached Board, we produce different grades of SBS that can be used in applications across a range of industries such as:

What is Bleached Board?

Folding Carton Platestock

Carded Packaging

Cupstock

Bleached Linerboard


Product End Uses


• Bring awareness to continually rising customer expectations in the industries we serve: Food, Hygiene, and Pharmaceutical

• Ensure that Bleached Board standards are clearly understood• To illustrate how to receive, handle, repair, store, and ship products

to meet or exceed our customer expectations• To assist our supply chain partners in reaching and/or maintaining

superior standards that are vital to doing business• Communicate the GP Bleached Board Expectations

Goals of this Document


Key Symbols

Immediate action required

Acceptable / Prime

Use a pack aid

Damaged Non-Prime

Wet Roll / Moisture Risk

Remove layers of rolls

Reject / Contaminated

Insect ContaminatedUse Kraft Tape


How to Read BB Roll Label


Roll IDGP = CompanyC - Mill (8=Brewton, C=Crossett, N=Naheola, S=St Marys)3 - Machine of production (1=BR, 2-9=CR, F-G=NA, H-K=SM4 - Last digit of yearM - Month (A=January, B=February except there is no month for I)12 - Calendar Date07 – Reel of the day1 – Set number within the reelZ – position within set (A=Front, Z=back)

Reading a Tappi Roll Label

Roll WidthRoll Diameter

Order Number

Weight in Pounds

Manufacturing Grade

***A SKU consists of a unique grade/width/diameter combination


On-time Shipment

Correct Quantity

Perfect Quality

The Perfect Order

CorrectDocumentation

The promised arrival date window is met.

The product is in exactly the correct quantity purchased.

The documentation accompanying the product is accurate.

The quality of the product meets “Zero Defects” criteria


• GP Bleached Board and our customers expect the product they receive to be free of contamination and damage

• The product is sensitive and easily damaged if our “Zero Defects” process and policies are not fully understood.

• The actions of our external partners in the supply chain have a direct result on the end user of the product.

• Contamination can be but is not limited to animal droppings, bacteria, chemicals, dirt, glass, grease, insects, metal, moisture, rust, and water.

When in doubt always STOP, THINK, & ASK

Zero Defects


• Fire Protection System with documented third party inspections• Overhead sprinkler systems are capped up above at the main where

possible (Fire Marshall approval required)• When not possible to cap at the main, all pole risers must be

guarded

Fire Protection

Rolls may not be stored in or near areas with unguarded valves on pole risers. Products on wood pallets may NOT be used to guard the pole


• Services provided by licensed provider. – Business and applicator licenses must be current and valid– Contract with details of pest management program

• Target pests for pesticide applications• Methods to prevent and eliminate pest problems• Frequency of visits for checking pest status• List of chemicals used

• Current map with location of control points with bait stations, and traps dated within 12 months.

• Service Records of visits– Summary of inspections, findings, treatments, and recommended action

plans during visit– Action plans issued by provider with actions required by warehouse

must be completed and closed within 90 days.

Pest Control


• GMPs are posted – Including signage designating areas for restricted activities:

• Smoking• Food/Drink• Hygiene

• Screens on open windows and doors. Doors closed when not in use.

• Waste Containers are clearly identified and not overflowing• Housekeeping practices ensure exterior and interior cleanliness.• Guarded or shatterproof lighting to mitigate potential glass and

brittles contamination.• Cross contamination is mitigated by storing GP product away from

potential contaminants.

GMPs and Housekeeping


• All vendor invoices should be submitted to Conduent SAP NACP NonFrt Single Inv

– [email protected]

• Invoice “Bill TO “header information– Header information should reference Georgia-Pacific Bleach Board LLC– Invoices are assigned to buyer based on header information

• Payments are issued based on date invoice is received by Georgia-Pacific– In conjunction with vendor payment terms– Vendor Payment terms were setup based on warehouse contact

• Invoice Payment Status – All inquiries should be directed to Bleach Board Accounting

• [email protected]• Please include copy of invoice• Primary Contact

– Gerrald Holland (404) 652-5830

Invoicing

mailto:[email protected]



Inventory Counts• Inventory should be organized

– Roll label ids should be visible– There should be sufficient space between rolls– Someone should be available to assist with moving rolls– Provide BOL’s for inventory discrepancies

Monthly Inventory Reconciliation• All reports/inventory inquiries should be submitted to Bleach Board Accounting

– [email protected]• Warehouse inventory reports should be received by the 5th working day each month• Bleach Board Accounting reconciles inventory on monthly basis• Warehouse is expected to assist with providing missing paperwork and/or support for

resolving inventory discrepancies• Damaged inventory needs to be identified on monthly reports• Converters also need to include butt rolls in the monthly reports

• Primary Contact– Gerrald Holland (404) 652-5830

Inventory



Issues with 944 Warehouse Stock Transfer Receipt Advice: 944 is not being sent for each 856. This results in manual receipts

or errors in processing 945’s as stock still shows in-transit in our system

944’s are being sent days after actual receipt. This forces a manual receipt if the trailer is needed for another load. Once the 944 is sent, it creates an error that as the load is already showing received and unload in our system

Issues with 945 Warehouse Shipping Advice: Examples of invalid data

o Shipping Order number sent with the original order line numbero Incorrect Weight or Lineal Measureo Invalid Roll Ido Roll Id sent with no Order Number or Customer PO Numbero Incorrect Shipment Id o Missing Seal #o Sending Original Order Line with no Original Order Number (This is not a required field

on the 945, but if sent, it must be correct.)

EDI Transactions Common Errors


Warehouse EDI Process: Specification Updates / Testing

• Periodic updates of the EDI specifications to improve the overall process and service to our customer

• All changes are tested with each warehouse • Engage warehouses to help test upgrades to our EDS tool which

processes our EDI documents • Partner with warehouses to test changes made to warehouse systems

Note: Please be diligent about denoting test files with a T as indicated in our EDI Profile. We have received test files in our production environment causing confusion for our business users.


• Self assessments are conducted at least monthly to ensure compliance to GP standards

• These assessments are completed through workflow notifications• Submitted assessments are reviewed by GP as part of quarterly

supplier scorecard.

Self Audits


Section 2: Inbound Inspections and Damage ReportingGuidance on how to handle inbound receipts and document incoming damage


• Before Unloading Check the Following Conditions are NOT present– Documentation and seal do not match– Clamp and floor where contact will be made with product is dirty or

contaminated– Strong odors are emitting from the container, railcar, or trailer– There is evidence of insect, bird, rodent, glass, or other contaminant

presence coming from container, railcar, or trailer– The Inbound vehicle condition is difficult to unload due to a load pattern

shift

Notify supervisor and GP immediately and do not unload if these conditions exist.

Inbound Receiving


• Ensure that unloading area is clean and sanitary. Keep area free of oil, dirt, and other contaminants.

• Always check your unloading equipment for leaks, or sharp edges that might damage the product.

• The most critical part of the unloading process is the inbound inspection. Ensure that all damages are observed, fixed if necessary, and reported at this stage.

• Make sure when unloading rolls, they are parallel to the floor before setting them down to avoid edge damage.

• Always use the correct PSI level for rolls in order not to “over clamp” them.

• Alert GP and take pictures if a railcar or truck arrives with a loading pattern that is difficult to unload.

• Report to railroad if you receive a class 1 railcar that needs servicing and immediate attention.

• Try to unload bleached board that has shifted or been loaded too tight in a railcar or truck (Advise concerned mill and ATL Supply Chain).

• Unload railcars or trucks in inclement weather, unless your facility has completely enclosed rail /truck unloading area.

• Drag or Slide rolls on any surface at any time while unloading.

• Ignore dents, holes and damage in railcars or trucks that you receive.

• Use more pressure on the bleached board with clamps than needed.

• Unload rolls without examining them on the top, sides and bottom. This is a crucial stage of quality control and must be done with minimum handling of the rolls.

Unloading of GP Bleached Board DO DO NOT


Unloading GP Bleached BoardDo Do Not

Store on clean surface Report difficult layout to GP

Stage on platform afterunloading

Clean loading / unloadingdock

Have contaminants near bleached board on docks and floors

Let bleached board bemoved without being parallel to floor


Inbound Receiving Product FlowInbound

Inspection

Repaired Damaged

Reject

Prime (Good)

Roll Contaminated?

Roll Damaged?

Is it Repairable?

Yes

Yes

Yes

No

No

NON-PRIME PRODUCT

Rework

PRIME PRODUCT

No


• PRIME– PRIME - Free of defects, includes tears in wrapping where there is no

damage to roll– REPAIRED – Rolls within GP BB repair tolerance that have been

repaired• NON-PRIME

– DAMAGED - Product exceeds GP BB repair tolerance but is notcontaminated

– REJECT – Contaminated (Contamination includes but is not limited to insects, oil, grease, glass, metal wood splinters, rust, damp or wet rolls)

Classification Categories of Received Product


DAMAGE CODES• HD - Header Damage

• CC - Crushed Core

• ED - Edge Damage

• WD - Water Damage

• SC - Side Cut Damage

• BD - Bottom Damage

• BED - Bottom Edge Damage

• CONT - Contaminated

These codes must be used when reporting

roll damage. Damaged product exceeds

repair tolerances but is NOT contaminated.

Reject: product is contaminated with bugs,

glass, water, oil, metal, wood, or other

embedded items.

Classification Codes of GP BB Damages

HDCC

ED

WD

BED

BD

CONT


Bleached Board is a sensitive product. Keep this in mind at all times!• Contaminants include but are not limited to:

– Glass or Metal pieces in the wrap or on the board itself– Bugs or Insects in the wrap or on the board itself– Oil and Grease on the board.– Pieces of paper from manufacturing processes such as core dust– Wood splinters– Rust on the bleached board– Damp or wet bleached board (swelling, or water marks)

What is Contamination?


Contamination – Oil and Embedded Objects

Issue: Wrap has oil mark on it

Solution: REJECT

Board is contaminated

Issue: Foreign object embedded in roll

Solution: REJECT



Contamination - Bugs

Issue: Insect under the wrap and on the board.

Solution: REJECT


Issue: Termites on the edge of the roll

Solution: REJECT VEHICLE

Board and vehicle are contaminated. DO NOT UNLOAD


Contamination – Water DamageIssue: Board has gotten wet.

Solution: REJECT

Roll is contaminated


Roll Damage – Crushed Core

Issue: Core is crushed

Solution: REJECT

Roll can not be repaired


• Damage and Contamination must be reported to GP within 24 hours of receipt of materials.

• Move damaged or contaminated material to a segregated area and leave there until disposition from GP which should be within 48 working hours.

• Damaged must be reported thru the Partner Portal Damage Log• Disposition will be provided by the mill and status updated within the

Partner Portal

Documenting Incoming Damage & Contamination


Section 3: Handling & Storage

Guidance on proper handling and storage of rolls


• The handling of the bleached board can have a key impact on the product. Good operating and storage conditions of the bleached board are important to making sure the customer receives the product in the same condition it was produced.

• From the time the bleached board is produced to the time the customer receives it, goes through multiple “touch points”. At these points, the bleached board has the potential to get damaged, at times beyond repair.

• These “touch points” are key areas to minimize damage, check for defects and also alert GP to issues you are seeing on the ground.

• Your focus on quality every time you unload, store or load bleached board is CRITICAL to the process.

• If you see something, say something. You have the authority to stop a shipment of bleached board you feel is not fulfilling our commitment to the customer. Remember, quality is EVERYONE’S business.

• Make sure there is a high level of communication between your facility and GP especially when product arrives damaged. Warehouses will be held accountable for product that is damaged and not reported to GP in a timely manner.

• When in doubt always STOP, THINK AND ASK. GP will strive to work as a team with outside vendors to make sure we keep the high standard of zero defects.

Handling and Storage of Bleached Board


• Ensure that unloading area is clean and sanitary.• Keep area free of oil and grease from equipment used for

unloading.• Make sure rolls are parallel to the floor before setting them

down.• Use a PSI level of between 1800 and 2300 on the rolls with

clamps to minimize damage (Suggested. Requirement varies based on load)

• Make sure upward & downward tension on the clamps has been removed prior to releasing the camps from the package” (This will keep the clamps from sliding down the package when the clamp pressure is released).

• Make sure the package is on the floor before releasing clamp pressure.

• Inspect every truck or railcar sent to you for safety and damage free condition.

• Alert GP and take pictures if a railcar or truck arrives with a loading pattern that is difficult to unload.

• Communicate to GP immediately if the railcar or truck unloaded is damaged or compromised (dents, leaks, etc.). Failure to do this might make you liable for roll damages.

• Keep re-handling of product to an absolute minimum.• Report to railroad if you receive a class 1 railcar that needs

servicing and immediate attention.• Let GP know the optimal pattern for unloading on your dock.

• Try to unload bleached board that has shifted or loaded too tight in a railcar or truck (Advise concerned mill and ATL Supply Chain)

• Attempt to handle rolls more than is absolutely required.

• Drag or Slide rolls on any surface at any time while unloading.

• Unload railcars or trucks in inclement weather, unless your facility has completely enclosed rail /truck unloading area.

• Store unloaded bleached board next to products that generate dust, odor and debris.

• Use more pressure on the bleached board with clamps than needed.

• Ignore dents, holes and damage in railcars or trucks that you receive. See something….Say something!

• Unload product without examining them on the top, sides and bottom. This is a crucial stage of quality control and must be done with minimum handling of the products

Handling of GP Bleached BoardDO DO NOT


Clamps are key attachments for handling bleached board. It is essential to keep them in clean and well-maintained condition always checking before use that there are NO sharp edges, dirt or other contaminants on the attachments that could damage or harm the roll.

Rubber clamp faces are highly recommended for handling rolls. If metal face is used, ensure that it is sanded down to a smooth surface. Herringbone clamp faces if used incorrectly cause a lot of stress and damage to the wrap of the product.

Ensure the stored clamps never have the clamp face itself set directly on the ground. It will damage the contact area.

Attachments | Recommended Standards


• ALWAYS store bleached board in a contamination free environment.

• Line floors with Kraft paper if there are dirt concerns• Regularly wash and clean floors around stored

bleached board.• Make sure that area the bleached board is stored in

is well lit.• Make sure that the bleached board is stored on

floors that are in good condition, free of cracks, debris, oil and grease.

• Place rolls in bays with labels facing forward for easy readability.

• Allow at least 3-4 inches of space between the stacks of bleached board to facilitate easy re-handling and prevention of overlapping rolls. Allow at least 18 inches between rows of stacks to allow one to walk entire row of stacks

• Store bleached board at least 3FT away from ceiling beams and poles to minimize potential for damage.

• Put damaged bleached board aside in a separate clearly marked area to be examined and/or repaired.

• Ever store bleached board on dirty, debris filled or oily floors. The potential for contamination is very high.

• Stack bleached board on floors that are uneven or have protrusions.

• Write on the outer wrap of the bleached board or put unauthorized labels or stickers.

• Stage bleached board that has visible damage

• Store bleached board on wooden pallets or by wooden objects.

• Stack bleached board tightly against walls, ceiling beams or any other hard objects that could damage the rolls

• Store bleached board in any manner that causes moisture or humidity to accumulate on or inside the wrap.

Storing of GP Bleached BoardDO DO NOT


Storing of GP Bleached Board Rolls - Do1. Store with labels facing out.2. Store rolls on clean floors, line

if necessary.3. Only use white or yellow chalk

to mark on paper wrap (Chalk must be wiped off prior to shipping out).

4. Maintain a minimum of 6” between stacks, preferred is 18”.

5. Maintain a minimum of 18”of stacks from wall.

6. Maintain a minimum of 36” from potential contaminants.

7. Have well defined segregation area for non-conforming products


Storing GP Bleached Board Rolls – DO NOT

Store near contaminants

Store against floor rails

Store against poles and racks

Store near contaminants



Store on dirty floors

Store on damaged floors

Offset stacks (No overhang)

Store on dirty floors



Store rolls on anything other than a flat, and clean floor

Mix with products that could create cross contamination or damage

Store rolls without labels facing out

Store rolls near damaged walls


Section 4: Rework & Repairs

Guidance on repair by defect type


• Understand the GP Bleached Board product guidelines. This is CRUCIAL.

• Carefully evaluate what can and cannot be repaired as per GP guidelines.

• Ensure the area for repair is clean and free of debris and other contaminants.

• Make sure that personnel in the warehouse are proficient with GP Bleached Board repair tolerances and procedures

• Make sure headers remain in tact. Replace if needed.

• Wear adequate and approved PPEs like safety glasses, and cut resistant gloves

• Always alert GP when questions arise about roll repair and keep the end uses of the board in mind when completing a repair procedure.

• Further damage or contaminate the board by repairing the product in an area that is dirty or open to other contaminants.

• Rush through a repair procedure which might make the damage look worse or unprofessionally done.

• Use unapproved materials and tools for the board repair.

• Ship roll that have not be repaired• Assume that a repair process for one GP

business is transferable to another

Repairing GP Bleached BoardDO DO NOT


Rework Toolkit

Contents of Rework ToolkitClear tapeDouble sided repulpable tapeHeadersKraft tapePack AidsPaper SlabberPaper Roll wrapRetractable knifeWhite tape

* Bold items provided by GP


Recommended PPEs Not Provided by GP

• Cut Resistant Gloves• Wire Mesh Face Shield• Heavy Duty, battery operated roll mover• Wheel Chocks


• Clear polypropylene patch provided by GP on pads of 25.

• Have adhesive around the perimeter of the patch with dead space in the center.

• Before applying a patch:– Make sure your hands are clean– Make sure the roll has been

prepared for repair– Make sure all tools are sharp and

clean– Ensure the patch itself is free of dust

and debris

What are GP “Pack Aids”?

Adhesive on edges


What Can be Repaired with GP Pack Aid?

A Pack Aid may be used when the poly wrap is torn and the board underneath is clean of dirt, debris, or other contaminants.


How to Correctly Use a Pack Aid

1. Cut the damaged poly wrap, ensuring you remove all dirt.

2. Place pack aid over open area and press firmly 3. Seal opening

1

1

2 3


Roll Damage – Poly Wrap

Issue: Poly wrap is torn

Solution: If roll is clean and uncontaminated, use up to 5 Pack Aids (patches) to fix.

REPAIR SHIP

Issue: Poly wrap is torn and layers of board are exposed and damaged.

Solution: Too much damage, potential contamination.

DAMAGED REJECT


Roll Damage – Busted EdgeIssue: Busted EdgeEdge of roll is busted and there is possible contamination

Solution: Roll can not be repaired. To many layers are damaged and there is potential contamination.

DAMAGED REJECT

Issue: Busted EdgeEdge of roll is busted and there is no contamination.

Solution: Roll can be slabbed and rewrapped if less than 2 inches from outer layer..

REPAIR SHIP


Roll Damage – Wrap Popped

Issue: Paper wrap has popped and is torn

Solution: If roll is clean and uncontaminated. Repair side with Kraft tape.

REPAIR SHIP


Roll Damage – Missing or Damaged Header

Issue: Header has come off or is missing.

Solution:

If end is clean, replace header and tape down.

REPAIR SHIP

If end is dirty, reject roll is contaminated.

REJECT


Roll Damage – Dirty RollIssue: Dirt or Debris noticed on or inside the wrap

Solution:

Attempt to brush off dirt without disturbing wrap first.

Cut outer layers if necessary to see if dirt is only between wrap layers or on the roll.

If only between wrap layers. Cut wrap use a pack aid or kraft tape to seal.REPAIR SHIP

If between board, REJECT CONTAMINATION


Roll Edge Damage

Issue: Edge of roll has indentation across multiple layers of board.

Solution: REJECT

Can not be repaired

DAMAGED REJECT

Issue: Bottom of roll has foreign object imbedded in it.

Solution: REJECT

BOARD IS CONTAMINATED


Issue: Edge of roll has wrap torn and dirty bleached board

Solution: Not repairable – multiple layers damaged/dirtyDAMAGED REJECT

Issue: Bottom of roll has oil and grease contamination

Solution: REJECT

BOARD IS CONTAMINATED

Roll Edge Damage


Roll Side Damage – Improper Repair

Issue: Roll wrap has been repaired in a manner that is not presentable to the customer.

Solution: REWORK

Can be shipped once wrap/tape is removed and professionally patched or repaired.

REWORK SHIP


Roll Side Damage – Damaged Layers

Issue: Roll has wrap torn and multiple layers of board are cut or torn.

Solution: REJECT

Roll can not be repaired. To many layers cut on side for rework.DAMAGED REJECT


Roll Side Damage – Torn Wrap and Layers 5 or less

Issue: Wrap is torn and layers are torn.

Solution: REWORK

If five layers or less and the board is not contaminated patch with Kraft tape or pack aid.

REPAIR SHIP


Roll Damage – Torn Layers 1”-2” in from outer layer

Issue: Wrap is torn and layers are torn on the edge.

Solution: REWORK

When there are more than six layers but less than 2” total damage from outside layer and the board is not contaminated, the roll can be slabbed, then rewrapped and shipped.

REPAIR SHIP


Roll Damage – Side Damage Issue: Side of wrap torn and multiple layers of board are torn.

Solution: REWORK

If 5 or less layers and board is not contaminated seal with pack-aid or kraft tape.REPAIR SHIP

If more than 6 layers but less than 2” layers then board can be slabbed, rewrapped, and shippedREPAIR SHIP

If more than 6 layers, and more than 2” layers then board cannot be repaired.REJECT


Roll Side DamageIssue: Side of roll has scuff marks on outer layer or wrap

Solution: Attempt to clean marks. Ensure no dirt has entered board. If board is clean. SHIP

Issue: One or more label is torn and barcode is not readable

Solution: Ensure that at least one label is visible and readable and contact GP if new labels are needed.SHIP


Roll Damage – Crushed Core

Issue: Core is crushed

Solution: REJECT

Roll can not be repaired


Section 5: GMP, Housekeeping, and Self AuditsGuidance on expectations for GMP and housekeeping practices, and how to conduct self-audit


• Have a housekeeping schedule that is followed and reviewed by area supervisor.

• Ensure housekeeping and cleaning activities include the removal of trash, dust, dirt, grease, oil, and water.

• Ensure that product is stored at least 18” from wall and area between product and wall remains clean and free of debris.

• Ensure that product is stored a minimum of 36” from potential contaminants

• Ensure spider webs are removed from walls and ceilings quarterly or as needed.

• Ensure trash is not overflowing and limit food waste to trash cans in designated eating areas.

• Ensure lawn care services includes weed control

GMP Expectations


Housekeeping PracticesDO DO

NOT

Clean, well-maintained, floors Cobweb-free ceilings Animal droppings Evidence of smoking in facility

Regular cleaning of floors Correct storage of equipment Trash on floors Damaged walls


Housekeeping PracticesDO DO NOT

Clean, well-maintained floors - store onlined floor

Well-segregated product

Non-Marking clamp truck tires

Oil-Free , smooth clamps

Sharp edges in bleached boardareas

Oily floors

Heavy dirt / debris on floors

Rubble on flooring


Housekeeping PracticesDO DO NOT

Clear signage in facility

Marked trash bins

Broken glass / signs Gaps under doors

Weeds inside or outside facility Trash inside facility


Screens and Dock Doors

Use screens on doors which are open but not in use. Truck and Rail doors must be down when no active loading/unloading and screen not in use.


• GP BB requires self-audits to be conducted at least monthly.• An email workflow notification will be sent on the 7th day of the

month that the self-audit is due.• A reminder notification will be sent on the 15th day of the month if it

has not been completed.

Self-Audits


Item Element Evaluation Criteria What to Look For Observation

1 Incoming InspectionRecords of Incoming Inspections

Record Review required. Roll condition documented on incoming including damage and contamination. Must include BOL, PO, and Roll IDs

2Segregation of Non-Conforming Product

Evidence of a designated area for non-conforming product

Clearly marked area(s) for non-conforming product. Visual confirmation that non-conforming product is contained within identified area

3 GMPEvidence of Good Manufacturing Practices

Are GMPs posted within the warehouse? Do GMP training records exist for operators?

4Outbound Inspection

Records of Outbound Inspections including railcars and trailers

Record Review required. Are inspections for outbound rolls done? Are railcars and trailers inspected prior to loading?

5 Exterior Cleanliness

Exterior is free of trash, weeds, standing water, obnoxious odors, and potential contaminents

MUST DO PERIMETER WALK. Is the outside is free of trash, weeds, standing water, obnoxious odors, and potential contaminents?

6 Interior CleanlinessEvidence of good housekeeping practices

of standing water, debris, excessive webbing, broken glass, and obnoxious odors? Is the trash is clearly marked and not overflowing? Are the floors clean? Date of last mop?

7Interior Walls and Floors

Evidence of structural integrity

MUST DO INTERIOR WALK. Observation that walls and floor are in good repair. No evidence of hole, deep cracks, or peeling paint

8 Roof IntegrityEvidence of structural integrity

MUST DO INTERIOR WALK. There are no holes, and no water leaks

9 Pest ControlEvidence of Pest Control Management

Name of pest control provider? Date of last service? Are there any open action items?

10 Windows and DoorsEvidence of screens to prevent contamination

Are there screens on all open doors and windows including dock doors? Are dock doors are closed when not in use?

Warehouse:Audit Date:

Individual Completing Audit:

Quality Control

Facility Conditions

Individual Reviewing Audit:

Self – Audit Checklist


11 Restricted AccessEvidence that access to warehouse is controlled

Is access to the warehouse controlled? How? Are there systems that prevent unauthorized entry such as locked doors, badge scanners, monitored entry ways, visitor identification, etc.?

12Glass and Brittles Policy

Evidence that lighting is guarded to avoid contamination

Is the lighting above GP product shatterproof or guarded? Does a glass and brittles policy exist?

13Appropriate Signage

Evidence of appropriate signage both interior and exterior

Does appropriate signage exists which identifies designated areas both inside and outside? This includes segregation area, smoking, food/drink, and hygiene

14 Designated Areas Evidence of compliance within designated areas

Are there designated areas for smoking, food/drinking? Is smoking prohibited within the warehouse? Is eating prohibited within the warehouse? Do signs exist instructing proper hygiene? Hygiene includes clean clothes for employees, and hand washing. Are sinks are available for hand washing?

15Cross Contamination

Evidence that GP product is stored in a way to prevent cross contamination with other products

Where is GP product is stored? Is it away from potential contaminents such as wood pallets, glass jars, odorous products?

16 Waste ManagementEvidence of appropriate waste management

Observation. Are waste containers clearly identified? Is waste contained to identified containers? Are the containers overflowing?

17 Fire ProtectionEvidence of Fire Protection System

Observation. Is there a sprinkler system? Are there valves on poles in the warehouse? If yes are these poles guarded? Are there fire extinguishers?

18 Dock Cleanliness Rail Dock ConditionIs the rail dock clean? Are there pallets on the dock?

19Moving/Handling Equipment

Evidence that moving/handling equipment is clean, safe, and appropriately maintained

Are all roll contact points (clamps, truck forks, floor, etc.) clean? What is the clamp pressure? What is the date of last service of the clamp truck? Who conducts the service of the clamp trucks?

Self-Audit Checklist


Section 6: Vehicle Inspection Procedures

Guidance on inspections for containers, railcar, or trucks to ensure product remains in “zero defect”


• Vehicle Inspections give guidance on what is – Typically safe to unload– Typically safe to load or reload– Conditions that may create issues of product quality or product safety

• This applies to all vehicles both OTR and Intermodal (containers, railcars, and trailers)

• Note: This information regarding loading and unloading safety provided in this section is provided as suggested guidelines for the warehouse consideration. Each warehouse is solely responsible for determining the safety of loading and/or handling of railcars, containers, and trailers at its facilities.

Vehicle Inspections


• Inspections must include the inside and outside of the vehicle• A checklist (hard copy or electronic) must be used. The following

areas are required and GP will check documentation for compliance– Floors and Crossmembers– Sidewalls– Roofs– Landing Gear– Doors– Other

• Date of last DOT inspection• Product inspection• Documentation verification (BOL, Seals)

• This applies to all containers, railcars, and trailers

Vehicle Inspection Checklist Requirements


Item Defect Specification

Floor Crossmembers Galvanic corrosion between mounting clip and baserail

Consider rejecting trailer if evidence of severe rust or corrosion is seen in critical attachments.

Floor Crossmembers Severely bent or cracked crossmembers Crossmembers should be spaced no more than 12” apart for loading roll stock. 6, 8, or 10 inch spacing is preferable. Consider rejecting trailer if any crossmembers are severely bent or cracked, or if spacing is more than 12” when loading dense material such as roll stock

Crossmember Fasteners Missing or damaged fasteners. Watch for shifted cross members where heads are intact but rivets are sheared

Steel rivets or bolts preferred over aluminum rivets. Consider rejecting trailer if any missing or damaged fasteners especially in center section of trailer between landing gear and rear wheels.

Post-to-baserailfasteners

Rivets with heads sheared off. Watch for tear which continues and cuts through a side post

Consider rejecting trailer if one rivet head is missing in a four rivet connection or if 2 or more heads sheared off in any 6 rivet connection

Baserail and side skin Baserail bent or cracked. Side skin cut, torn, or otherwise damaged

Consider rejecting trailer if damage to baserail or side skin exceeding about 21 inches is not structurally repaired. (Note: Caulking or sticky aluminum is not a structural repair)

Landing Gear Severely bent or broken bracing Consider rejecting trailer if any bracing is bent excessively or any bracing connections are broken. IMPORTANT: Use trailer support jacks if tractor is not connected. Move tandem wheels to rear to help prevent tipping forward of trailer.

Landing Gear Missing or damaged fasteners Consider rejecting trailer if any rivet heads are sheared off or any fasteners are missing.

Doors Locking mechanism damaged Consider rejecting trailer if door cannot be properly closed and locked

Door Gaskets or seals damaged Consider rejecting trailer if door gaskets or seals will not completely seal out dirt and water around doors

Inspection Guidelines – Outside Trailer


Areas of the Trailer Bottom Rail

Slide Area Bay Area Coupler Area


Types of Bottom Rail

HD Bottom Rail 15-18 inches tall STD Bottom Rail 6-10 inches tall


Vehicle Inspection Exteriors

Acceptable Areas of major repairs or sectioning

Inspect the top and bottom rail for all of the following criteria:Any and all visible damageAny failing existing repairsAny existing repairs that are not reinforcedAny inappropriate or incorrect repairsAny minor cracks in the bottom railAny damaged, loose, missing, or incorrect fasteners


Bottom Rail Inspection Criteria – Visible Damage

A Vertical Crack

Typically safe to unload if floor rib has not been broken

A Waved Bottom Rail

Typically safe to unload if the floor rib has not been broken

A Horizontal Crack

Typically safe to unload if over the coupler of slide areas


Bottom Rail Inspection Criteria – Existing Repairs

A Missing Section Repair:

Typically safe to unload and reload if less than 12 inches long and the floor rib has not been broken. Must be Back-Plate reinforced in the bay area.


Back-Plates

NOT Back-Plate Reinforced

A Missing Section Repair

Typically safe to unload and reload if less than 12 inches long and the floor rib has not been broken. Must be Back-Plate reinforced in the bay area.

Back-Plate Reinforced in Bay Area


Damaged Cross-Members

One cross-member in the bay area that is cracked at the web connection to the end plate is still typically safe to unload. Two cross-members next to each other is typically unsafe to unload


Plate Bolted on the Outer Face of the Bottom Rail

A Plate Bolted Over Damage:

Typically safe to unload and reload if located in the coupler or slide areas


Bottom Rail Inspection – Minor Cracks

A Minor Crack:

If the crack is less than ½ inch long trailer is typically safe to unload. Does not require Back-Plate reinforcement.


Bottom Rail Inspection – Damaged, Missing Fasteners

Damaged or Missing Fasteners:

If two bottom rail-crossmember fasteners are damaged or missing on a single crossmember in the bay area, trailer is typically unsafe to unload until the fasteners have been replaced.

More than 3 missing fasteners in the side panels to the bottom rail trailer is typically unsafe to unload.


Major Damage in the Bay Area

Major Damage in the Bay Area:

A full height crack or a missing section that has broken the floor rib.

The trailer is typically UNSAFE to unload.

Bay Area


A Three Piece Bottom Rail

A Repair that results in a 3 piece Bottom Rail:

The trailer is typically UNSAFE to unload


Crack in the Slide or Coupler Area

A Full Height Crack in the Slide or Coupler Area:

If located in the slide or bay areas after back-plate reinforced is typically safe to unload.

Do Not Reload


Bottom Rail Replacement Procedure

3/8 Carriage Bolt withRibbed Shoulder

T45 Torx Head Bolt withStepped Shoulder


Stop Crack Hole in a Vertical Crack

A Vertical Crack:

If located in the slide or bay areas after a 3/16 stop crack hole is drilled in the end of the crack and back plate reinforced it is typically safe to unload.


Stop Crack Hole in a Horizontal Crack

A Horizontal Crack:



A Missing Section of Bottom Rail

A Missing Section of Bottom Rail:



Eye Brow Cracks Over the Cross-Members

Eye Brow Cracks over the Crossmembers:

If 4 or less in a row, after back-plate reinforced trailer is typically safe to unload


Back-Plate Reinforcement

24 inches or 2 cross-members either direction of the Splice Repair


Inspection Guidelines – Inside TrailerItem Defect Specification

Floor Delaminated floor area Do not drive lift truck wheels over areas of suspected floor delamination

Floor Wavy Floor May indicate a bent or cracked cross member. Investigate further and if necessary reject trailer

Floor Wet Spots Could be leaks from roof or nose. If in floor usually indicates delamination or leak at butt joint. Reject trailer.

Floor Holes; broken floor boards None allowed. Reject trailer

Roof Bent, broke, or missing roof bows Consider rejecting trailer if one or more roof bows is missing or severely bent or broken in the middle 1/3 of the trailer

Roof Cracked or damaged roof sheet Reject trailer If roof sheet cracked or slit and unrepaired

Roof Holes (light showing through) None allowed. Reject trailer

Nose Smooth, flat (vertical) face. No evidence ofwater leaks

Reject trailer if risk of causing product contamination or damage

Sidewall Rough or jagged plywood Consider rejecting trailer if risk of causing product damage

Sidewall Bowed In wall Consider rejecting trailer if risk of causing product damage


Vehicle Inspection: Patched FloorsDO DO NOT

These patches being at the back and only reaching the firstseam is high risk to load. All patches should be long enoughto be secured to a minimum of4 Cross Members.

This patch reachingthe second seammakes it a goodpatch that we canload without issues.

This patch coversmultiple crossmembers whichmakes it a goodpatch that we canload without issues.


Vehicle Inspection: Damaged Floors*Examples of floors that can NOT to be used for GP Bleached Board product

Damaged floor Damaged floor Damaged floorDamaged floor

Nail not flush with floor Cracked flooring Cracked flooring Excessive Oil on Floor Check with finger if it transfers.

IF Transfers REJECT


Vehicle Inspections: Damaged Roofs

Bad roof patch Rusting roof Poor roof patch with rust developing

Bad roof patch

Leaking roof Hole in roof, light is visible

Leaking roofHole in roof, light is visible


Vehicle Inspections – Damaged Walls

Bent cross member Bent cross member

Hole in sidewall Mold on sidewall

Rusty sidewalls

Bad wall patch


Vehicle Inspections – Sidewall Damage

Hole in wall that can not be patched with tar tape, and is larger than a pinhole.

Wall is bowed in, may damage rolls

Wall is bowed out, and no punctures


Vehicle Inspection Summary•Ensure 2 whole cross members are always covered if patch is present. •Always REJECT “wavy” floors even if patches are not present.•Floors with scratches or small portions missing up to 1 layer are OK.•Excessively oily containers are not to be brought to the mill.•Tar tape procedure to fix holes only pinpoint size. If no tar tape procedure in place, REJECT.•If no holes present, streaks on walls are OK.•Bowed in walls to be REJECTED.•All cross members to be inspected.•Any cracks noticed underneath the floor to be REJECTED.

Severely bent cross member

Floor showing cracks below

DO NOT LOAD

DO NOT LOAD


Rail Car Inspection Guide – Moisture Risks

HoleHole

LeakLeak


Rail Car Inspection Guide – Moisture Risks

Light Visible

Hole

Light Visible

Light Visible


Rail Car Inspection Guide*Examples of what NOT to be used for GP Bleached Board product

Summary• Make sure the inside is contaminant

and debris free.

• Check for holes and sharp edges inside the car.

• Check walls for dirt and contaminants.

• Make sure door are undamaged.

• Ensure the rail car doors are properly latched prior to transit.

• Take care to make sure there is no forklift damage to the cars.

This rail car must be rejected dueto wooden walls and floor

This rail car must be rejected due to the metal track along the floor. This car must be rejected due to the amount of contaminants and trash.

This car must be rejected due to the contaminant found on the walls.Unwrapped rolls would certainly become contaminated with this dark


Section 7: GP BB Load Plans & Load Best Practices


• The following load plans are approved configurations used by the mills meant to give some guidance as to how to load BB rolls in containers, intermodal, and dry van trailers.

• It does not cover every possible load configuration for BB rolls.• These load plans only apply to GP Bleached Board.• These load plans identify the number of spots. When determining

how to load a vehicle first consider the number of spots on the floor and secondly the total load weight.

• The dunnage recommended is approved by GP and used by our mills. Each warehouse is responsible for selecting and using dunnage for that meets domestic and/or international transportation requirements and protects the product from damage and contamination in transit.

Overview


BB Load Plans – 48” diameter in 53’ Container/Trailer/Intermodal

22 spots on the floor1st roll offset to left and then continue to offset rollsDunnage:2 36” x 17’ friction mats

Place first roll in second layer


BB Load Plans – 48” and 50” diameter in 40’ ContainerFor 48” diameter = 18 spots on floorFor 50” diameter = 17 spots on the floor1st roll offset to left and then continue to offset rollsDunnage:2 36” x 17’ friction mats


BB Load Plans – 58” and 60” diameters in 53’ Container/Trailer/Intermodal

For an EVEN number of rolls12, 10, 8, 6 spots on the floor1st roll offset to left and then continue to offset rollsDunnage:2 36” x 17’ friction mats


BB Load Plans – 58” and 60” diameters in 53’ Container/Trailer/Intermodal

For an ODD number of rolls11, 9, 7 spots of the floorA 5 spot load pattern is not approved1st roll in the middle then offset to left then right then continue to offset rollsDunnage:2 36” x 17’ friction mats Place first roll in second layer


BB Load Plans – 58” and 60” diameter in 40’ Container9 spots on floor1st roll offset to left and then continue to offset rollsDunnage:2 36” x 17’ friction mats



BB Load Plans – 69” and 70” diameters in 53’ Trailer/Container/Intermodal

9 spots on the floorOffset 2, 2, 2, 2, single Dunnage:2 36” x 17’ friction mats



BB Load Plans – 69” and 70” diameters in 40’ Container

7 spots on the floorOffset 2, 2, 2, single Dunnage:2 36” x 17’ friction mats



BB Load Plans – 72” diameter in 53’ Container/Trailer/Intermodal

8 spots on the floorOffset 2, 2, 2, 2Dunnage:2 36” x 17’ friction mats



BB Load Plans – 72” diameters in 40’ Container

7 spots on the floorOffset 2, 2, 2, single Dunnage:2 36” x 17’ friction mats



Section 8: GP Audits


• Goals and Objectives of the Audits– Check compliance to GP Standards– Ensure Customers receive products that meet their expectations– Ensure Warehouse meets our product quality and product safety

requirements while ensuring that safety, documentation, housekeeping, and product repair are performed at the highest levels

• Types of BB Audits– Qualification Audit– Annual Compliance Audit– Revisit (Audit Follow Up)– Complaint

GP BB Audits


Internal Procedures, Documentation, & Training

3rd Party Certifications

Self-Audits

BB Warehouse Standards & SOPs

Training

Fork Training

Communication & Responsiveness

Vehicle Condition Inspections

Vehicle Load Best Practices

Pest Control

Fire Protection

Product Handling

Product Inspections

Segregation of Non-Conforming Product

Non-Conforming Product Process

Rework/Repair

Condition of Prime Stock

Facility Conditions Risk Assessment

Exterior Cleanliness

Visibility of Major Contamination

Interior Cleanliness

Structural Integrity – Walls & Doors

Structural Integrity – Roof

Condition of the Floors

Windows and Doors

Contamination – Pests

Contamination – Glass & Brittles

Cross Contamination

Odorous Conditions

Restricted Access

Appropriate Signage

Designated Areas for Restricted Activities

Waste Management

Dock Cleanliness

Moving/Handling Equipment

Management Focus

Structure of a Annual Compliance Audit

0 High Risk Present Urgent Attention Needed

2 Risk Present Urgent Attention Needed

4 Does not meet criteria

6 Partially meets criteria

8 Meets Criteria

10 Exceeds Criteria

> 211 Approved

185 < 210 Conditional

< 185 Not Approved

Element Score

Audit Score


• All audits are scored by element and overall• Overall Audit Score determines categorization and if additional

action is required• When identified action is required an action plans is due to GP

within 30 days. Documentation or revisit is required to close open actions from audits.

Audit Scoring and Required Actions


• Corporate:– Accounting - Gerrald Holland [email protected] 404-652-5830– Customer Service - Keith Dula [email protected] 404-652-5157– IT - Michelle Aguirre [email protected] 423-838-6210– Quality - Tara Spivey [email protected] 404-353-3417– Supply Chain - Arthur Little [email protected] 404-652-5960– Technical Service - Wayne Rhodes [email protected]

• KBX– Lisa Needler [email protected] 404-652-6189

• Mills:– Brewton

• Bryant Winn [email protected] 251-809-7356• Tony Woods [email protected] 251-809-7337

– Crossett• Scotty Pennington [email protected] 870-567-8156• Monty Kilcrease [email protected] 870-567-8194• Morrell Freeze [email protected] 870-567-8508

– Naheola• Melissa Compton [email protected] 205-459-1513• David Cho [email protected]

– St. Mary’s• Missy Brazell [email protected] 912-673-0211• John Delano [email protected] 912-673-0217

GP Key Personnel Contacts

















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