Packaging, Shipping & Field Installation Checklist

This checklist is prepared to prevent damage, quality loss, or user errors during the transportation, storage, and field installation stages of hardware products. The goal is to ensure that the product's journey from factory to customer is safe, traceable, and compliant with standards.

Packaging Design and Material Selection​

1. Is the packaging design optimized according to product dimensions and fragility level?​

Packaging design should be planned considering the product's weight, dimensions, fragility level, and transportation orientations.

At least 25–50 mm buffer space should be left around the product, and this space should be filled with shock-absorbing materials.

For heavy products, double-wall corrugated or composite boxes should be used for ease of handling. Packaging dimensions should be optimized for both pallet layout and transportation vehicles.

2. Has the outer packaging material passed durability tests (Box Compression / Drop Test)?​

The outer boxes used should pass Box Compression Test (BCT) and Drop Test procedures.

• BCT: Box's resistance to vertical pressure (minimum 250 kgf)
• Drop Test: 6-direction drop from 76 cm height (ISTA 1A standard)

These tests verify the packaging's safety against crushing or deformation risks during transportation.

3. Are internal protection materials (foam, EPE, antistatic bag, etc.) selected appropriately for the product type?​

Appropriate internal cushioning material should be selected for the product's fragile areas (e.g., PCB, display, glass surface, connectors).

Examples:

• EPE / EPS → Shock absorption
• PU Foam → Surface protection and flexible support
• Antistatic bag (ESD Bag) → For electronic modules

Material selection should be determined according to product type and weight distribution, and should not create unnecessary volume. All internal protection parts should be repeatable through CNC cutting or molded production.

4. For products requiring antistatic (ESD) protection, are ESD bags, labels, and markings provided?​

ESD protection is mandatory for products containing electronic circuit boards, sensors, or RF modules.

The product should be:

• Placed in an antistatic bag (pink bag / shielding bag)
• Marked with ESD warning label (⚡) and directional arrows
• The packaging floor should be conductive or groundable material

This precaution protects components against static discharges during transportation.

5. Are packaging materials recyclable or compliant with environmental standards (ISO 14001)?​

All materials used in packaging (cardboard, foam, plastic bags, tape) should be recyclable or environmentally harmless.

The packaging should display:

• Recycling symbol ♻️
• Material code (e.g., PAP 21, LDPE 4)

Additionally, the manufacturer should have ISO 14001 or similar environmental management system certification. This practice is important for both corporate sustainability and CE/ROHS compliance.

6. Does the packaging have product orientation, fragility warning, and stacking limit labels?​

International transportation symbols (ISO 780) and directional labels should be present on the package's exterior:

• "This Side Up" (Direction arrow)
• "Fragile"
• "Keep Dry"
• "Max Stack: 4 Boxes" (Stacking limit)

Label positions should be placed where they will be visible during transportation (top and two side faces). Missing warning labels increase the risk of improper handling in the logistics chain.

7. Does the packaging design provide vibration absorption during transportation (according to ISTA standards)?​

Packaging vibration resistance should be verified with ISTA 3A / ASTM D4728 tests. Vibration frequencies in the 5–200 Hz range that can occur during transportation are particularly risky for sensitive electronics.

Internal support materials should have density and hardness to dampen these vibrations. If necessary, rubber isolators, air cushions, or multi-layer internal packaging design should be applied. Test results should be documented with a "Vibration Test Report".

Labeling and Traceability​

8. Does each product box have model number, serial number, and revision information?​

Each individual product package should contain model number, serial number (SN), and revision information (Rev).

This information is mandatory for product traceability and warranty coverage.

Example label content:

Model: AGRO-CTRL-100
Serial No: SN2025-004512
Rev: B

This information should be present in both barcode and human-readable format. The revision number should match exactly with the product content (e.g., PCB or firmware version). Missing or incorrect numbering can cause errors in service and warranty processes.

9. Are barcode or QR code systems integrated with shipment tracking?​

All product boxes and main cartons should be integrated with barcode (EAN-13, Code128) or QR code systems. These codes, when connected to ERP or WMS (Warehouse Management System), can include:

• Production date
• Batch (lot) number
• Customer ID or order number

This system enables automatic traceability throughout the shipment chain. QR codes can also be used to direct to technical documentation, warranty registration, or installation pages.

10. Are packaging labels formatted according to ISO 780 and IEC 82079-1 standards?​

All warning and informational labels on the packaging should comply with ISO 780 (Handling Symbols) and IEC 82079-1 (Preparation of Instructions) standards.

These standards define the rules for labels' symbols, language, size, and placement.

Labels should include:

• Product orientation (↑ This Side Up)
• Fragility (Fragile)
• Temperature range
• Humidity or pressure limits
• Recycling symbols

Labels should be UV-resistant and moisture-resistant, not easily erasable.

11. Are product documents (user manual, warranty, certificates) properly placed inside the packaging?​

Each product box delivered to the customer should contain these documents:

• User Manual
• Warranty certificate
• Compliance certificates (CE, RoHS, ISO, IP, etc.)
• (if applicable) Quick Start Guide

Documents should be placed in a separate envelope or cardboard pocket to protect against moisture or tearing. Additionally, the document language should comply with the legal requirements of the country where the product is sold (e.g., local language requirement in the EU).

12. Is the packaging content list (packing list) attached to the outer label or carton?​

A packing list listing the products contained should be added to each carton or pallet.

This list should include:

• Product code
• Description
• Quantity
• Serial numbers

The list should be attached externally to the carton in a transparent envelope for visibility. This practice saves time during customs, warehouse acceptance, and shipment inspections.

13. Is each package linked to the ERP system with production lot number?​

Each packaging unit should be linked to the ERP (Enterprise Resource Planning) system with the lot number generated during the production process.

This connection enables:

• Product–production date matching
• Serial-based quality control
• Recall or warranty tracking

to become automatic. Lot numbers should be readable via barcode/QR code and immediately recorded in the ERP. This system meets full traceability requirements.

Palletizing and Loading​

14. Is the palletizing layout planned according to transportation optimization (based on center of gravity)?​

Palletizing layout should be optimized for both transportation safety and warehouse space efficiency. Boxes should be placed with their centers of gravity aligned, and heavier products should be at the bottom with lighter products on top.

Product weight distribution should be planned to prevent pallet tipping or bending risks. Symmetrical placement prevents unbalanced load formation during transportation. A "Pallet Layout Drawing" should be prepared and approved during logistics planning.

15. Are pallet material and dimensions compliant with international standards (EUR/ISO pallet)?​

All pallets should be in EUR 1 (1200 × 800 mm) or ISO 1 (1200 × 1000 mm) dimensions.

Material preference:

• Wood (ISPM 15 heat-treated)
• Plastic (recyclable, for hygienic environments)
• Metal (for shipments requiring high durability)

Manufacturer, dimension, and certification information should be readable on pallet edges. Wooden pallets must carry ISPM 15 (Heat Treatment) stamp before export. Non-standard pallets can create incompatibility with storage and transportation equipment.

16. Are packages secured on pallets with anti-slip materials (stretch film, corner protectors)?​

All palletized loads should be secured against slipping or tipping during transportation.

Recommended securing methods:

• Stretch wrap — 2–3 wraps around entire load, including top closure
• Corner protector — Prevents cardboard deformation
• Anti-slip sheet — Provides friction between boxes

Packaging wrap should also cover the lower pallet edges. Pallet stability should be checked to withstand 0.5 g acceleration test (ASTM D6055 reference).

17. Is bottom support or double pallet system applied for heavy products?​

For products weighing more than 300 kg, bottom reinforcement (reinforced base) or double pallet system should be used to prevent load sagging and collapse.

Bottom support elements:

• MDF / plywood sheet
• Steel support profile
• Plastic reinforcement plate

This system prevents pallet cracking or bending and increases transportation safety. Additionally, for heavy loads, at least 100 mm clearance should be left between forklift forks.

18. Are forklift or pallet jack entry directions marked on packaging labels?​

The directions from which pallets will be carried by forklift or pallet jack should be clearly indicated with labels or symbols.

Example symbols:

• "Forklift Entry This Side"
• "No Entry"
• "Lift Here"

Lifting from the wrong direction can cause pallet base structure breakage or product tipping.

19. Is pallet loading height within appropriate limits for the transportation vehicle (max 1.6–1.8 m)?​

Pallet heights should be limited according to the internal volume of transportation vehicles and safe stacking limits.

General rule:

• Maximum height: 1.6–1.8 m
• Maximum pallet weight: 1000–1200 kg

High pallets cause collision risk inside trucks or containers. Height limits should be clearly stated in the "Loading Plan" document.

20. Is the loading plan shared with the transportation team?​

The Loading Plan prepared before shipment should be shared with the transportation team and warehouse managers.

This plan should include:

• Pallet placement order
• Load center of gravity points
• In-vehicle securing points
• Gap-filling materials
• Estimated weight and stacking limits

A copy of the plan should be added to the shipment file and signed by the transportation manager. This practice eliminates damage or imbalance risks caused by incorrect loading.

Transportation Conditions and Logistics​

21. Are temperature and humidity ranges defined during transportation (e.g., 5–40 °C, below 70% RH)?​

To prevent product damage during transportation, permitted temperature and humidity ranges should be clearly defined.

Example: "Transport conditions: 5–40 °C, below 70% RH (non-condensing)."

These values should be added to packaging labels and transportation documents. Particularly for products containing batteries, sensors, or optical components, moisture condensation is a critical risk.

22. Is a temperature/humidity data logger placed when necessary?​

For long-distance or sensitive shipments, a data logger (temperature & humidity data logger) should be placed inside the packaging.

These devices record environmental conditions during shipment, allowing post-transportation analysis. They should generate alarms when threshold values are exceeded or provide visual warnings through color change.

Records should be added to post-delivery quality control reports. For critical shipments, adding shock indicators or tilt sensors is also recommended.

23. Are vibration, tilt, or shock risks on the transportation route evaluated?​

The transportation route should be analyzed according to transport type (land, air, sea).

• Land transportation: continuous vibration (5–200 Hz)
• Air transportation: low pressure + temperature difference
• Sea transportation: high humidity and tilt effect

These risks should be evaluated using Vibration Profile Analysis method. For routes with high vibration or tilt risk, additional reinforcement (foam pad, damping plate) or double packaging should be used. This evaluation should be documented as "Route Risk Assessment Report".

24. Does the transportation company have appropriate insurance for the product class?​

Shipment should be covered by cargo insurance appropriate to the product's value and risk class.

Insurance policy should include:

• Product type and FOB/CIF value
• Transportation method and route
• Packaging type
• Policy duration and coverage scope (damage, loss, delay)

Insurance documents should be added to the shipment file and shared with customer or distributor. ICC (A) coverage is recommended for international shipments.

25. Is training provided against collision/drop risks during loading and unloading?​

Loading personnel should be trained on the product's sensitivity class, lifting points, and handling instructions.

Training content should include:

• Forklift fork distance
• Transportation direction (with arrow symbols)
• Balance control during lifting
• Post-drop or collision reporting procedure

These trainings should be recorded and included in the "Material Handling SOP" document.

26. Are transportation documents (waybill, MSDS, export certificates) submitted with the packaging?​

Mandatory transportation documents for each shipment should be delivered with the packaging:

• Waybill / Invoice / Delivery Note
• MSDS (Material Safety Data Sheet) – for products with chemical content
• Export / Customs certificates (CE, CoO, RoHS, REACH)
• Packing List

Documents should be attached externally to the carton in a moisture-proof plastic envelope. Missing documents can cause customs or delivery delays.

27. Are customs labels (HS Code, CE, WEEE) completed for international shipments?​

For international shipments, legally required labels and markings should be present on product packaging:

• HS Code (Harmonized System Code) – customs classification
• CE marking – European compliance
• WEEE (Waste Electrical and Electronic Equipment) symbol
• (if required) UKCA, FCC, or EAC markings

Labels should be resistant to erasure, UV light, and moisture; at least 10 years of readability life should be targeted. All labels should be checked according to "Label Specification Sheet" document.

Storage and Warehousing​

28. Is the storage area compliant with temperature, humidity, and ESD conditions?​

Environmental conditions of the storage area should be controlled according to product characteristics.

Recommended general limits:

Temperature: 10–30 °C
Relative Humidity: 30–70% RH (non-condensing)

ESD protection measures are mandatory for electronic products:

• Antistatic floor coating
• Grounded shelf systems
• ESD wristband or glove use

Storage area should be regularly monitored with calibrated sensors and recorded.

29. Are pallets not in direct contact with the floor, separated by rack system?​

Pallets should not be in direct contact with the floor; they should be stored on rack systems, grid bases, or height barriers (10 cm or more). This precaution protects products against floor-sourced moisture, water leakage, or heat transfer.

Additionally, contactless storage facilitates forklift access and increases air circulation. Warehouse plan should be organized according to fire safety and air flow rules (NFPA 13, ISO 11601).

30. Is maximum storage duration defined for stocked products?​

Maximum shelf life (storage life) should be determined for each product type and recorded in the stock management system.

Examples:

• Electronic boards: 12 months (in sealed ESD packaging)
• Battery modules: 6 months (half-charged, 20–25 °C)
• Plastic enclosures: 24 months (UV-protected)

Products exceeding this period should undergo re-inspection or functional testing process. Storage duration should be monitored with automatic alerts in the ERP system.

31. Is FIFO/FEFO system applied in the warehouse?​

FIFO (First In, First Out) or for perishable materials FEFO (First Expired, First Out) principle should be applied in stock management.

This way, old production batches are used before new shipments, preventing material aging or revision confusion. Each product box's production or entry date should be on the packaging label.

ERP system should automatically suggest FIFO/FEFO ordering during shipment. This approach is particularly critical for products with firmware or hardware revisions.

32. Is packaging sealed durability tested for long-term storage?​

If the product will be stored for a long time (e.g., more than 1 year), the packaging's sealing and protection durability should be tested.

Test types:

• Water Vapor Transmission – ASTM F1249
• Package seal integrity test – ASTM F2096
• UV resistance test – ISO 4892

These tests verify that packaging does not cause deformation, color fading, or static charge buildup during long-term storage. Additionally, packaging samples should be opened for periodic quality inspection every 12 months.

Field Installation and Initial Commissioning​

33. Are installation instructions (Installation Manual) included in the packaging?​

Each product should be delivered with detailed Installation Instructions (Installation Manual) to be used during field installation.

This document should:

• Explain installation steps in sequence
• Include visuals, connection diagrams, and warning signs
• Separate electrical and mechanical assembly procedures

The manual should be accessible both in printed form (inside packaging) and digitally (QR code or web link).

34. Are connecting elements (screws, washers, cables) needed for installation completely provided?​

All connecting elements needed during installation (e.g., screws, nuts, washers, cable sets) should be provided with the product.

These parts should be numbered in a separate "installation kit" package and listed. Missing hardware can cause installation delays and improper field installations.

All kit contents should be checked against the Packing List before unpacking. Additionally, torque values and connection methods compatible with the used parts should be clearly stated in the manual.

35. Are ESD, grounding, and safety precautions clearly stated during installation?​

Electrical safety and ESD protection steps should be detailed in installation procedures.

Mandatory precautions:

• Antistatic wristband use
• Grounding point check
• No connections before power disconnection
• Avoiding sharp corners or metal contact during cable routing

These precautions should be marked with warning symbols (⚡ / ☣ / ⚠) in the manual, and the "Safety Notes" section should be prepared according to ISO 7010 symbols. Additionally, it should be verified that personnel received ESD training before installation.

36. Are required tools and special equipment listed in the manual for installation?​

All tools needed during installation should be clearly stated in the manual.

Example:

• PH2 screwdriver, 5 mm Allen key, torque wrench (0.5–1.5 Nm), multimeter
• For special installations: tightening fixture, alignment pin, ESD mat

This list ensures complete and safe installation. Inadequately specified requirements can lead to wrong tool use and product damage. Additionally, recommended model or standard (e.g., IEC/ISO number) should be specified for each tool.

37. Are installation time, personnel count, and test steps planned?​

Estimated installation time, required personnel count, and task distribution should be pre-planned.

Example: "Installation time: 45 minutes – 2 people (1 electrical technician, 1 mechanical assembler)."

This information is important for field planning, service contracts, and cost estimation. Additionally, pre-test steps to be performed after installation completion (power, connection, LED check, communication test) should be included in the plan document. This plan should be stored as "Installation Work Instruction" in the project management system.

38. Are post-installation functional test steps included in the manual (e.g., power, communication, LED check)?​

Functional tests to be performed after installation completion should be explained step by step in the manual.

Basic tests:

• Power-up (Voltage check)
• LED status check
• Communication test (UART, RS485, CAN, Ethernet, Wi-Fi)
• Sensor reading / data flow verification
• Protection fuse check

Each test step should be documented with a checklist containing "PASS/FAIL" field. Functional tests should be consistent with factory pre-shipment tests (Factory Acceptance Test – FAT reference).

39. Is software/firmware version checked during field installation?​

During installation, the device's firmware version should match the approved version defined in the system.

Example: "FW Version: v1.12 (Required: v1.10 or higher)"

This check prevents device–network incompatibility or protocol errors. Firmware version can be specified in the manual or on digital label (QR/Barcode). If necessary, OTA (Over-the-Air) update or USB flash update procedure should be provided. Version number should be recorded on the installation form.

40. Is the "Site Acceptance Test (SAT)" form filled out upon installation completion?​

After installation, a Site Acceptance Test (SAT) form should be filled out to document that the system was delivered in working condition.

This form should include:

• Tested functions
• Measurement results
• Software/firmware version
• Field engineer and customer approval

SAT form should be archived in the quality management system (e.g., ISO 9001) as delivery approval. Additionally, the digital version of the form should be uploaded to ERP or project management system. Installation should not be considered complete without SAT approval.

Service and Return Process (Reverse Logistics)​

41. Is the return (RMA) procedure clearly stated inside the packaging or on the user portal?​

With each product or on the online user portal, the RMA (Return Material Authorization) procedure should be clearly stated.

This procedure should explain step by step:

• How to report the return reason
• How to obtain RMA number
• How to package the product and which address to send it to

Different process flows should be defined for user error, non-warranty failures, or manufacturing defects.

42. Is safe transport packaging defined for service (anti-shock packaging)?​

Anti-shock protection packaging to be used for transporting products returned under service or warranty should be determined.

This packaging ensures the product can be returned without physical damage.

Recommended features:

• EPE or PU foam internal support
• Antistatic bag (ESD Sensitive Products)
• Shock indicator label (ShockWatch / Drop Indicator)
• "Return for Service" label

If the original packaging is not available, a reusable service box should be provided to the user.

43. Are service/replacement products associated with serial numbers?​

Every product processed in service or replacement should be associated with the original serial number (SN).

This association should:

• Be matched with RMA number in ERP or CRM system
• Be archived with post-service test results

New or repaired products must be clearly marked with "Refurbished" or "Replacement" label. This practice provides traceability in warranty period tracking and quality root cause analyses.

44. Do returned products undergo re-testing and certification process?​

All products received under RMA should undergo post-service re-testing and re-certification processes if necessary.

Test scope:

• Electrical and functional tests
• Visual and mechanical damage check
• Software/firmware version check
• EMC and safety tests (if required)

Successfully passed products can be restocked, failed ones should be directed to recycling process instead of storage.

45. Is packaging return / reuse policy defined?​

As part of corporate environmental policy, a recycling or reuse policy for packaging materials should be established.

Policy should include these objectives:

• Recyclable material ratio in packaging 80% or higher
• Packaging return option to user (e.g., deposit system)
• Sterilization and reuse procedure for returned packaging

This process should comply with ISO 14001 (Environmental Management) and EU Packaging Waste Directive (94/62/EC). This policy should be transparently shared on the company website or in product documents.