Quality Manual

Table of Contents

Incoming Quality Control (IQC)

In-Process Quality Control (IPQC)

Finished Goods Inspection Standard (OQC)

Shipping Inspection Report Sample

Non-Conforming Product Control

Customer Complaint Handling + 8D Report

Continuous Improvement Mechanism

Incoming Quality Control — Raw Material Inspection

1.Process Flow

2.Sampling & Testing Requirements

Wood ：Moisture content (8%-12%), Density, Check for insect holes & cracks

Fabric：Abrasion resistance (≥25,000 cycles), Color fastness (≥Grade 4), Flame

retardant report

Foam/Sponge ：Density (35D-45D), Resilience rate (≥40%), Formaldehyde emission (≤0.05mg/m³)

Hardware ：Salt spray test (48 hrs, no rust), Load capacity (≥1.5 × rated value) .

In-Process Quality Control — Manufacturing Gates

1. Cutting & Preparation Self-Inspection (Operator):

Dimensional tolerance: measure length/width/thickness at 3 points each, error ≤±1mm;

Material defects: check for wood knots, cracks, color variation — separate non-conforming pieces;

IPQC Sampling (5 pcs every 2 hrs):

Re-check critical dimensions with caliper;

Verify cut surfaces are smooth, no burrs;

Spot-check that non-conforming items are correctly segregated.Assembly & Framing

Assembly & Framing

Self-Inspection:

Even glue application at tenon joints, pressing time ≥30 seconds;

Frame placed on flat surface — all four legs touch ground, no warping;

Shake test: no looseness or abnormal noise when rocking left-right.

IPQC Sampling (3 pcs per shift):

Tensile test: tenon joint strength ≥150N without separation;

Check glue overflow: exterior overflow ≤2mm width and cleaned.

Upholstery & Finishing

Self-Inspection:

Fabric tautness: press by hand, no wrinkles, immediate rebound after release;

Sewing inspection: check both sides for skipped stitches, broken threads, loose threads;

Hardware installation: screws tightened properly, hinges operate smoothly.

IPQC Sampling (3 pcs every 2 hrs):

Corner safety check: measure R-angle with gauge, ≥2mm;

Overall shake test: place finished product on floor and push, no wobbling

or abnormal noise.

Inspection Record Form

Each shift completes the IPQC Patrol Record Form, documenting: time,

workstation, sampled quantity, passed quantity, failed quantity, corrective actions. Dual sign-off by Team Leader and IPQC Inspector.

Outgoing Quality Control — Final Inspection Standard

Outgoing Quality Control — Final Inspection Standard

Inspection Method:

Appearance: 100% inspection — every piece visually checked;

Function: Per AQL sampling, test per batch per product at specified ratio.

OQC 17-Point Checklist

1. Overall appearance ：View from 1m: no scratches, stains, color spots；

2. Dimensional accuracy ：Measure L/W/H at 3 points each, deviation ≤3mm；

3. Structural stability ：Place on flat surface, no wobble when pushed; load test

+20%；

4. Surface treatment ：Smooth to touch, no exposed nails or screws；

5. Upholstery quality ：Fabric taut and even, no wrinkles；

6. Sewing quality ：Even stitches, no skipped stitches, no exposed thread ends；

7. Hardware function ：Screws tight, hinges operate 3 × smoothly without sticking；

8. Load capacity ：Place 1.2 × rated weight, hold 30 min without deformation；

9. Corner safety ：All exposed corners, radius ≥2mm, not sharp to touch；

10.Labeling ：Product label straight, text clear, content correct；

11.Packaging integrity ：Carton undamaged, tape sealed securely；

12.Accessories completeness ：Per BOM: screws, foot pads, instruction manual all present；

13.Color consistency ：Compare to approved sample, no visible 色差 (≤Grade 1)；

14.Odor check：Open package and smell, no pungent chemical odor；

15.Cleanliness test ：Wipe surface with damp cloth, no fading, no pilling；

16.Scratch resistance ：1kg load scratch head, 5 cycles, coating no peeling；

17.Instruction manual ：Correct text, clear diagrams, correct language version。

Acceptance Criteria:

Non-Conforming Product Control

1.0 PURPOSE

To establish a standardized workflow for identification, segregation, root cause analysis, disposition, and prevention of non-conforming products.

2.0 SCOPE

Applicable to all production processes, incoming materials, and in-process / finished goods within the facility.

3.0 DEFINITIONS

NCR: Non-Conformance Report

IPQC: In-Process Quality Control

5-Why: Iterative root cause interrogation technique

MES: Manufacturing Execution System

WIP: Work In Process

4.0 PROCEDURE

Step 1 — Identification & Segregation

Any employee discovering a non-conforming product shall:

Attach a red "NON-CONFORMING" label stating: Finder, Date/Time, Defect Description, Work Station.

Move the product immediately to the Red Non-Conforming Area.

Prevent any mixing with conforming inventory.

Step 2 — Documentation & Reporting

Initiate an NCR using the format: NCR-XXX.

Capture a minimum of 3 close-up photographs of the defect.

Report to the Team Leader and IPQC Inspector within 30 minutes for

on-site confirmation.

Step 3 — Root Cause Analysis (5-Why)

Conduct successive "Why" analysis until the root cause is determined.

Document the complete chain of causation and the final root cause statement.

Step 4 — Corrective Actions

Immediate Action: Contain the defect and correct the condition (e.g., recalibrate machine, sort affected lot).

Short-term Action: Implement workplace controls (e.g., fix-mount checklists, supervisory verification).

Long-term Action: System-level prevention (e.g., MES integration, automatic lock-out).

Step 5 — Disposition

Step 6 — Closure & Prevention

Enter data into the Monthly Quality Analysis Report.

Trigger Supplier Audit or ECR if recurrence reaches 3 consecutive events.

Present as a Monthly Quality Meeting case study and conduct follow-up

training.

5.0 RECORDS RETENTION

NCR records, photographs, and disposition approvals shall be retained for a minimum of 3 years or as defined by customer / regulatory requirements.

Customer Complaint Handling & 8D Report

Complaint Response Process

Received → Acknowledge within 24 hrs → Interim countermeasure within 48 hrs → Submit 8D within 5 working days → Complete correction within 15

working days → Follow-up call to confirm customer satisfaction

Contact Information

Customer Service Email: harryh@ywhow.cn

Phone/WeChat: +86 186 0301 9518

Commitment: Respond within 24 hrs on working days; Emergency issues

within 12 hrs

Continuous Improvement — Quality KPIs & Annual Review Annual Quality Targets (2025)

Monthly Quality Analysis Mechanism

Meeting: 5th of every month

Attendees: General Manager, Quality Manager, Production Manager, Engineering Manager, Purchasing Manager

Agenda:

Previous month KPI achievement — red/green status

Top 3 defect issues of the month — Pareto chart display

Customer complaint review — read customer feedback verbatim

Corrective action progress check — incomplete items flagged red

Next month priority prevention projects — assign to individuals

Customer Complaint Statistical Analysis

Customer Complaint Ledger records each complaint:

Complaint date, customer name, product model, problem description

Defect cause classification: Material / Process / Design / Packaging / Shipping / Other

Loss amount: Rework cost + Shipping cost + Customer claim + Reputation

loss

8D report number, closure date, customer satisfaction score (1-5)

Quarterly statistical analysis:

Which category has highest proportion → Allocate resources to resolve

Which supplier has most issues → Initiate supplier audit

Which product model has most issues → Engineering design review

Improvement Case Library

10 typical improvement cases annually, compiled into the Annual Quality Improvement Report, including:

Problem and data before improvement

Improvement measures and investment

Data after improvement and comparison charts

Lessons learned, extended to similar products

Report published every January, company-wide training, outstanding cases rewarded ¥500-2,000.

Shipping Inspection Report — Sample

Sample 1: Standard Outgoing Inspection Report

出货检验报告

Outgoing Quality Control (OQC) Report

Sample 2: Pre-Shipment Container Loading Checklist

装箱检查报告

Pre-Shipment Container Loading Inspection Report

8D Report