The quality of interior components is paramount, directly impacting customer perception, vehicle safety, and long-term durability. Our quality control system is a comprehensive, integrated process spanning from development to final assembly.
1. Advanced Product Quality Planning (APQP): Quality is engineered from the start. We employ Design for Manufacturability (DFM) and Failure Mode and Effects Analysis (FMEA) to proactively identify and mitigate risks in part design, material selection, and assembly processes before production begins.
2. Incoming Material Control: All materials—including plastics, leather, fabrics, foams, adhesives, and metals—are rigorously tested against OEM specifications. Tests cover colorfastness, grain consistency, tensile strength, flame retardancy, VOC emissions, and resistance to UV light, heat, and abrasion.
3. In-Process Manufacturing Control: Production processes are monitored using Statistical Process Control (SPC). Key parameters such as injection molding pressures/temperatures, die-cut dimensions, stitch quality, and adhesive application are continuously tracked. Sensory quality (visual, tactile, auditory) is assessed at dedicated stations under standardized lighting (D65). Geometric conformity is verified with frequent checks using CMMs (Coordinate Measuring Machines) and laser scanners.
4. Sub-Assembly & Functional Testing: For complex modules (e.g., instrument panels, center consoles, door trim), sub-assembly verification is critical. We test all mechanical functions (hinge movement, latch operation), electronic components (switches, lighting, displays, sensors), and HVAC integration (airflow, vent operation). Dimensional, Functional, and Aesthetic (DFA) checks are performed.
5. Final Audit & Containment: A final audit simulates the conditions of the automotive assembly line. Parts are checked for fit-and-finish with mating components, surface defects (scratches, sinks, voids), color match, and overall presentation. Robust containment procedures, including packaging audits, prevent shipping of non-conforming products.
6. Traceability & Continuous Improvement: Every part or batch is traceable to its production data. Any deviation triggers a root-cause analysis and corrective action (CAPA). Feedback from the OEM assembly line is integrated to drive continuous process refinement.
Our goal is to deliver interior components that consistently meet stringent aesthetic, functional, and safety standards, ensuring total customer satisfaction and vehicle integrity.