CMYKC+MM+YC+Y3435SPOT

SS27 · SHEET EDGE · GRACoL

Tern is an invented brand. The manual is by Carlos Vasquez, who ran projects and did the prepress at a real print studio.

TERN OUTDOOR — INTERNAL · DISTRIBUTE TO VENDORS UNDER NDA

DOC TN-OPS-SS27 · REV C · PAGE 1/1

Tern

Packaging & branding operations

Season manual · SS27 · four categories · three factories

FIG. 0 — footwear box, one-piece tuck · cut · fold

One manual, the whole season: what ships, on what substrate, through which reviews, from which factories, by when. Every decision the season needs is written in it.

Season calendar

six milestones · one season

M1Season kickoff — scope + categories locked✓ Feb 09
M2Creative review 01 — packaging concepts✓ Mar 16
M3Routing — legal · proofing · translations · compliance✓ Apr 27
M4Factory handoff — specs, dielines, mockup approvals — we are hereJun 08
M5On-press — press checks, drawdown approvalsAug 17
M6In DC — samples archived, season retroOct 05

Routing

every artwork walks this line

Legal

Claims, marks, regulatory copy. One reviewer, 48-hour SLA.

2 working days

Proofing

Content vs. master spec, dieline fit, color targets called out.

3 working days

Translations

FR · DE · JA · ES. Locked glossary; no re-flow after approval.

5 working days

Compliance

Fiber sourcing, market labeling, recyclability marks by region.

4 working days

Fourteen working days door to door. Each station has one owner and one SLA, and artwork never enters two stations at once.

Spec library

click a spec — the manual opens

— cut · -- fold

Dimensions: 330 × 115 × 120 mm · glue flap 18 mm · auto-lock bottom
Substrate: 100% recycled kraft, 350gsm, unbleached
Sustainability: FSC Recycled · soy inks · zero laminate
Version: v4.2 — earlier versions archived, never deleted
Note: Single material by design. No window or coating, so it recycles curbside everywhere we ship.

Vendors & factories

OTD and samples, straight from the log

Partner	Region	Scope	On-time	Samples archived
Alderline Print Co.	Portland, OR	Folding carton · offset	98.4%	41
Kite Paper Group	Guadalajara, MX	Kraft converting · flexo	96.1%	27
Marumi Packaging	Osaka, JP	Labels · specialty stock	99.2%	18
Fieldline Install	National, US	Retail signage programs	97.8%	12

Every physical sample earns a shelf label and a photo in the archive. When a factory asks which version, someone reads the code off the shelf label.

The SOP shelf

every runbook fits one page

01Press check, one page — targets, sequence, sign-off line1 page
02Vendor onboarding — specs, portals, first-article checklist1 page
03Routing runbook — who approves what, and in which order1 page
04Sample archive — how a physical sample earns a shelf label1 page
05Translation lock — glossary first, artwork second, never both1 page

None of these runs longer than a page.

Press & color standard

the page the pressroom reads first

Method: G7 gray balance · offset & flexo masters per substrate
Tolerance: ΔE00 ≤ 2.0 solids · ≤ 3.5 overprints, measured M1
Proof: Contract inkjet proof, verified wedge on every sheet
Viewing: D50 booth only — no approvals on the shop floor lights
Brand green: PANTONE 3435 C · builds 92/38/78/32 coated kraft
Screening: 175 lpi conventional · stochastic on kraft recycled

File prep — rejected at preflight if not met

3mm bleed on every cut edge; type 4mm inside the fold
Rich black 60/40/40/100 — never four-color from the vendor file
Minimum line weight 0.25pt positive, 0.5pt reversed
Dielines on a spot layer named CUT, set to overprint
Live text outlined; fonts never travel with the file

Drawdowns — this week’s pulls

3435 on kraft

ΔE 1.4 · PASS

3435 on coated

ΔE 0.8 · PASS

Spot rust

ΔE 1.9 · PASS

Rust on kraft

ΔE 3.1 · REPULL

Rich black

ΔE 0.6 · PASS

Press check — sheet 042, footwear box, Alderline press 2

Color bar measured — every patch inside ΔE00 toleranceRegistration clean at all four corners, 10× loupeSheet matches the contract proof under D50Slur and star targets sharp — no doubling, no dragContent verified against approved artwork, version and all

the page wins — 0 of 5 checked

The sheet has to agree with this page before anyone signs it.

Preflight bench

run a vendor file against the rules

Pick a file — the bench runs section 06’s rules and prints the verdict.

Capacity & season health

demand vs capacity · rebalanced weekly

Station	Capacity	W28	W29	W30	W31	W32	W33
Legal	10 files/wk	60%	40%	80%	50%	30%	20%
Proofing	14 files/wk	85%	95%	112%	70%	55%	40%
Translations	8 files/wk	50%	75%	100%	88%	38%	25%
Compliance	9 files/wk	45%	55%	70%	65%	80%	30%

W30 overloads proofing: wholesale sell-in samples and the mailer reroute land in the same week. The rebalance, decided Monday: hangtag v7 reproof pulled forward to W29 and the mailer proof moved to Kite’s desk — W30 lands at 96% and the press date never moved.

On-time delivery

95.4%

season to date · target 95.0

Rework

2.8%

of releases · last season 4.6

First-pass preflight

31%

clean on arrival · see the bench

Proof cycles

1.4

per asset · target ≤ 1.5

Surfaced this week — risk, impact, decision

Rust-on-kraft repull (ΔE 3.1) puts M5 drawdown approvals at risk. Second pull scheduled W29; if it misses again, we change the substrate rather than loosen the tolerance.
Kite converting runs tight W30–31 (regional holiday). Mailer volume shifted to Alderline: cost +4%, press date held. Decision logged with the program lead.

The board is rebalanced every Monday.