QUALITY / MANUFACTURING PROCESS
Quality control begins before mass production and continues throughout manufacturing.
At Xinyinhai, incoming checks, first article approval, workshop inspection and final QA have defined responsibilities. Inspection criteria, recorded decisions and approval requirements connect each stage.
A process overview based on the factory’s internal inspection documents.
01 / THE PRODUCTION FLOW
OEM and ODM quality control connects material acceptance, production approval and finished-product decisions. Process-specific checks take place within production.
IQC checks incoming materials and outsourced parts against engineering requirements and reference samples.
Control purpose An acceptance or rejection decision is recorded before materials move into production.
Inspect function, appearance, consistency and applicable safety requirements on the first submitted products.
Control purpose Normal batch production is authorized only after the first article is accepted and approved.
Inspectors review production requirements, patrol the workshop and sample output during production.
Control purpose Abnormalities are reported and addressed while the process is running.
Assigned inspectors cover plastic molding, COB / bonding / SMT, soldering, printing and assembly.
Control purpose These responsibilities operate within production to prevent nonconforming work reaching the next process.
For toy finished goods, inspect packaging, appearance, function and applicable safety requirements.
Control purpose Final QA records defects, counts and the lot acceptance decision.
Accepted results and signed inspection reports provide the quality basis for release.
Control purpose Rejected lots require disposition. Test specimens covered by the finished-product safety test procedure are excluded from shipment.
The workbook documents inspection acceptance and production approval. It does not define a separate logistics dispatch authorization procedure; “release” here refers to the quality acceptance basis.
02 / ACCOUNTABILITY
Quality responsibility is assigned at process level, with management and engineering support for inspection decisions and improvement.
Organization reference
WI-COP1.1-11
03 / BEFORE PRODUCTION
IQC provides an acceptance or rejection decision for raw materials, auxiliary materials and outsourced or subcontracted parts.
Check dimensions, function and technical parameters, then compare color, printed content and surface condition with engineering drawings or samples. Materials with specified reliability tests follow the relevant laboratory submission requirement.
The warehouse initiates the incoming inspection report. IQC records sampled defects, their classifications and the decision. Rejected materials go through the documented disposition and, where needed, review process.
IQC reports incoming quality abnormalities to suppliers and Purchasing and periodically evaluates supplier performance.
The linked material standard is a separate document with a different MIN AQL value. See the document-specific sampling notes before applying either reference.
04 / THE PRODUCTION APPROVAL GATE
Starting a line does not authorize normal batch production. Production submits the first articles; inspectors check them, record the results and obtain approval.
FIRST ARTICLE ACCEPTANCE
Under the first-article standard, one failing specimen on any inspection or test item makes the submitted first-article batch unacceptable.
Failed first articles are reviewed with Engineering and Production. Corrected first articles are produced and submitted again.
WI-COP-7.1.1-01 · §§6.3, 6.6The first-article standard routes approval to Engineering. The patrol standard routes it to the quality lead, with Engineering approval for a new product’s first production run. Both require approval before batch production.
Restart is also an approval point. The production-management procedure requires a first-article check for each production work order before normal production and when production resumes after an interruption. Record confirmation before restarting the batch; a previous approval does not replace this restart check.
05 / APPLICABLE TOY PRODUCTS
For products exported or sold as toys, the first-article standard specifies safety checks according to the destination market. Higher customer test requirements take precedence.
Check applicable toy products under the small-parts test work instruction.
Apply where a product or component may present a sharp-point hazard during normal use or abuse.
Evaluate the relevant parts under the specified pull-test procedure.
Apply the prescribed pressure-test procedure for the product and market.
Evaluate applicable toy products under the relevant drop-test instruction.
These are standards referenced in the supplied internal documents for applicable products and markets. They do not establish certification or compliance for every product. The applicable edition, product scope and customer requirements need to be confirmed for the project.
06 / DURING PRODUCTION
In-process quality control (IPQC) brings patrol checks into manufacturing. Inspectors use the production notice, technical documents, work instructions and approved samples to assess current work.
Review production requirements and reference documents, then confirm and record the first article before normal batch production.
Check operator work against SOP / SIP requirements and sample current output. After the QC control-point inspection passes, patrol sampling must also pass before workshop output enters storage.
Record production abnormalities and inspection results, escalate issues and coordinate corrective action with Engineering. Reworked rejected lots require reinspection.
07 / ASSIGNED AT THE PROCESS
Electronics quality inspection and plastic product quality control have assigned workshop responsibilities. Each inspector judges conformity and works to stop nonconforming products entering the next process.
08 / FINISHED GOODS
Final QA checks the finished lot and records its acceptance decision. The supplied Finished Product Inspection Standard, WI-COP-8.2.4-01, explicitly covers toy finished goods.
Outer cartons, individual packaging, correct components, missing accessories and packaging damage.
Surface condition, color, scratches, molding defects, housing fit and assembly workmanship against the reference sample.
Legibility, completeness, print color, product descriptions and required warning information.
Specified product functions, switches, sound or display where relevant, and conformity to the product requirements.
Correct label content, placement and quantity; date-code content, marking method and position.
Conductive debris, other foreign material and contamination in or on the product and packaging.
Applicable mechanical safety tests, accessible points or edges, battery-related hazards and required safety markings.
Correct parts, nameplates, battery specifications and agreement with the required model and approved sample.
The final inspection report records test results, defect descriptions, defect counts and the decision. The inspector and relevant production supervisor sign the report before it is filed.
09 / DEFECT CLASSIFICATION & AQL
The definitions below summarize the finished-product standard. Where a unit has more than one defect class, it is counted under the highest severity. Individual defect criteria still govern classification.
A safety defect that may cause serious injury or illness during assembly, operation or use, or fail legal or regulatory requirements.
A functional or appearance defect that may make the product unsaleable and is likely to cause returns, significant customer dissatisfaction or discontinued orders.
A noticeable defect unlikely to cause returns or complaints, but which may negatively affect the customer’s view of product quality.
The workbook specifies single sampling and General Inspection Level II for general checks. Incoming and final inspection explicitly use normal sampling plans.
Final carton selection uses Special Level S-4, with enough cartons opened to supply the planned sample. The first-article sample is 6 pieces per submitted batch; the final safety-test sample is also 6 pieces.
AQL labels are not measured defect rates, sample sizes or guarantees. Lot size and the applicable sampling table are needed for a lot decision.
| Defect class | AQL |
|---|---|
| Critical (CR) | 0 |
| Major (MAJ) | 0.65 |
| Minor (MIN) | 1.0 |
The incoming and finished-product standards reject the lot when a Critical defect is found. First articles have their separate all-items-pass rule.
10 / DOCUMENTED INSPECTION STANDARDS
This overview draws on Xinyinhai’s supplied Quality Control Process workbook. Document identities provide the basis for the summary without publishing the full internal procedures.
WI-COP1.1-11
Defined management, engineering, IQC, process inspection and final QA duties.
WI-COP-7.1.1-01
Version B · Quality Department · revision shown: 28 December 2017.
WI-COP-8.2.4-01
Version F · Quality Department · revision shown: 28 December 2017.
The workbook also contains Incoming Inspection and Patrol Inspection standards, both labeled WI-COP7.5.1-02, Version D. That repeated identifier is retained as a source limitation. The displayed revisions are historical document references; the supplied workbook does not verify current revision status.
11 / NONCONFORMITY & RELEASE
A failed result needs an identified owner, a contained lot and an approved disposition. The documented procedure covers incoming materials, production, finished goods, customer inspection failures and returns.
Mark rejected materials or products and keep them in the designated rejected area or container. Record the defect and affected quantity. Incoming rejections go to Purchasing and production planning for return or formal review; customer-supplied material is referred to the customer for disposition.
The review may authorize return, sorting, rework, conditional use, downgrade or scrap as applicable. Engineering contributes the technical assessment; authorized management approves the decision. Material review must not introduce a safety hazard. Customer agreement is required when specified by the order or when customer interests are affected; concessions for rejected finished goods require recorded customer agreement.
Failed first articles are corrected and resubmitted for approval. Repaired work in process must pass its assigned inspection before the next operation. Sorted and repaired finished goods return to Quality for inspection. After a customer inspection failure, internal inspection must pass before arranging customer reinspection.
Inspection and review records retain the issue, approved action and result; status identification is updated to match. Downgraded goods remain identified and separate. Final QA follows rejected-lot treatment. Under the finished-product safety test procedure, tested specimens are scrapped and cannot be shipped with bulk goods.
These are documented controls, rather than a report of completed dispositions. See Traceability & Materials for the relationship between status identification, production records and the agreed traceability scope.
12 / CORRECTIVE & PREVENTIVE ACTION
Correcting one lot addresses that lot. Corrective and preventive action (CAPA) addresses the cause and the risk of recurrence, with follow-up evidence before closure.
Major quality problems, customer complaints or returns, audit findings and abnormal data trends can initiate action. The responsible department investigates the cause and proposes measures for Quality review before implementation.
Quality tracks implementation and the result, with the action register supporting follow-up. Unsatisfactory action remains open. Closure requires confirmation; preventive measures also require their effectiveness to be verified.
Once measures are confirmed effective, permanent changes are incorporated into the relevant controlled procedures and instructions. Inspection trends and audit follow-up inform further review of the process.
For a supplier review: request an appropriate completed example connecting the issue, cause, approved action, verification and any document revision. The Quality Management System overview explains how document control, competence and management review support these decisions.
13 / BUYER QUESTIONS
Practical answers for sourcing, engineering and quality teams planning an OEM or ODM product.
The documented process combines incoming material inspection, first article approval, workshop patrol inspection, process-specific inspection and final QA. Inspection results support acceptance, rejection and follow-up decisions. The finished-product standard summarized here applies to toy finished goods.
IQC is responsible for inspecting raw and auxiliary materials and subcontracted parts. Checks include dimensions, function, technical parameters and appearance against engineering requirements or samples. Results are recorded, and incoming quality problems are reported to suppliers and Purchasing.
Yes. Production submits first articles for inspection. Under the first-article standard, all inspection and test items must pass; one failing specimen on any item makes the submitted first-article batch unacceptable. Results and samples are submitted for approval before normal batch production is authorized.
Assigned inspectors review production instructions, technical documents and samples, confirm first articles, patrol operations and sample production output. The supplied patrol standard specifies checks at two-hour intervals in the workshops it covers. Abnormalities are recorded and escalated, and reworked rejected lots must be reinspected.
The toy finished-product standard covers carton and individual packaging, appearance, printing, marking, function, specification consistency, foreign material, labels and date codes, plus applicable safety checks. Final QA records defect descriptions, counts and the lot decision in a signed report.
In the finished-product standard, Critical defects concern safety or legal requirements. Major defects are functional or appearance problems likely to make a product unsaleable or cause returns and significant dissatisfaction. Minor defects are noticeable issues unlikely to cause returns or complaints. A unit with several defect classes is counted under its highest severity; individual inspection criteria still govern the decision.
Yes. The supplied process workbook specifies single sampling, General Inspection Level II for general checks, and AQL labels CR 0, MAJ 0.65 and MIN 1.0 for incoming, in-process product sampling and final inspection. Final carton selection uses S-4. These values are specific to this workbook: the separate incoming-material reference published on this site lists MIN 2.5. Confirm the applicable document and customer requirements for the order; the values are not interchangeable.
For applicable toy products, the first-article standard lists Small Parts, Sharp Point, Tension, Compression and Drop Tests. Sharp-point testing is conditional on the relevant hazard. Requirements depend on the product, destination market and customer criteria; the documents reference ASTM F963 for the USA and EN71 for Europe. These references do not establish certification or universal product compliance.
Failed first articles are reviewed with Engineering and Production, corrected and resubmitted. Production abnormalities are recorded and escalated for action; rejected production lots are reinspected after rework. Rejected incoming materials follow the documented disposition and review process. Final QA monitors rejected-lot follow-up and retains the inspection decision.
The first-article, patrol and finished-product standards provide for customer inspection requirements or acceptance levels higher than the factory’s requirements. Share the specification, drawings, reference sample, target market and expected acceptance criteria so the applicable requirements can be reviewed for the project.
The nonconformity procedure requires a documented review and authorized disposition. A concession for rejected finished goods requires customer agreement recorded in the review. Material reviews must not introduce a safety hazard, and customer agreement is required when the order calls for it or customer interests are affected. Production urgency alone is not an approval.
The responsible department identifies the cause and proposes corrective and preventive measures for Quality review. Quality follows implementation and effectiveness; closure requires confirmation. Effective permanent changes are incorporated into the controlled documents so the revised method remains in use.
YOUR NEXT OEM / ODM PRODUCT
Bring your product requirements, drawings, samples, quality expectations and target market into the discussion before tooling and mass production.
Open the project checklist, or download a copy to complete and share with your existing project contact. Downloading a checklist does not submit an inquiry.
