Golden Sample Approval SOP: AQL Checklist, 0.1mm Flash Limits, Leakage & Drop Testing
A golden sample is not just a photographic prototype—it is the legally binding engineering benchmark for your entire mass production run. Ap…
1. Three-Tier Sample Quality Inspection SOP
| Inspection Dimension | Test Methodology & Tooling | Acceptance Quality Limit (AQL / Threshold) | Verdict Standard |
|---|---|---|---|
| Flash & Parting Line | Optical Magnifier / Tactile Check | Parting line flash ≤ 0.10 mm, zero sharp burrs | Critical Defect (AQL 0) |
| Thread Torque & Fit | Digital Torque Meter | Smooth engagement, tightening torque 1.5 - 2.5 N·m | Major Defect (AQL 1.0) |
| Inverted Leak Resistance | Fill 50°C water, invert for 4 hrs + 100 shakes | Zero droplet leakage, vacuum valve normal | Major Defect (AQL 1.0) |
| Color Accuracy (ΔE) | Spectrophotometer vs. Pantone C | ΔE ≤ 0.8 across multiple components (PP/Silicone/PPSU) | Minor Defect (AQL 2.5) |
| Print Abrasion Resistance | 95% Ethanol + 500g load, 50 double rubs | Zero ink peeling, fading, or edge blur | Major Defect (AQL 1.0) |
| Suction Base Adhesion | Digital Force Gauge Vertical Pull | Peak vertical pull force ≥ 35N on smooth glass | Major Defect (AQL 1.0) |
| Free Drop Impact | 1.2m drop onto concrete (1 corner, 3 edges, 6 faces) | Zero body cracking, collar detachment, or leakage | Critical Defect (AQL 0) |
2. Golden Sample Sign-Off & Change Control Protocol
Dual-Party Sealing:Sign and seal 3 physical identical sample sets (1 for Buyer QC, 1 for KOBOY Production Line, 1 for Quality Archive). All sets must include dated labels and revision numbers (e.g., Rev 1.2).
ECN Change Protocol:Any subsequent color change, mold insert revision, or packaging adjustment must be documented in a formal Engineering Change Notice (ECN). Verbal approvals are strictly prohibited.
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