SITCOM QUALITY CONTROL MANUAL(draft version)

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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
_____________________________________________________________________________________________________________



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QC Manual


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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
_____________________________________________________________________________________________________________

Introduction
This quality control manual, hereafter known as QC Manual, was created as a reference
document to ensure that all vendors adhere to Sitcom quality standard, and Sitcom quality
control process. QC Manual is used as instruction document for Sitcom QC staff/Sitcom Agent
and Sitcom vendor to refer during production and quality control process.



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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
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CHAPTER 1
SAMPLE DEVELOPMENT PROCESS
1.1 Sample development flow
Drawing is sent to
vendor from Sitcom.

Vendor make sample

Not Passed

Checked by
Sitcom QC or
PD

Not
Approved

Passed
Sitcom QCM to take photos of
MS, document it and sent to
sitcom PD, KSDIV1 for approval
and record.

Signed off Master Sample by
PD or QCM

Vendor Improve
product or packing

Checked
by Sitcom

PD

Not
Passed Vendor conduct in-house
quality test, drop test with
Sitcom QC/Agent
Passed

Vendor send samples for
MTL test if required by
Failed Sitcom

Approved

Passed
Sitcom QC/Agent to take pictures,
document then send to Sitcom PD for
approval

Passed

End

Checked by
Sitcom PD

Approved

3

Not
Approved

QC Manual


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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
_____________________________________________________________________________________________________________

Note:
QC
: Quality Control
PD
: Product Development
QCM : Quality Control Manager
1.2 Sample Development Flow For Resourced Items
For old items that resourced to new vendor the sample development flow will be as below
Old product is sent to
vendor from Sitcom.

Vendor make sample

Not Passed

Checked by Sitcom QC
or PD (Interchange test,
dimension, construction,
workmanship)

Not
Approved

Passed
Sitcom QCM to take photos of MS,
document it and sent to sitcom PD,
KSDIV1 for approval and record.

Signed off Master Sample by PD
or QCM

Vendor Improve
product or packing

Not
Passed

Vendor conduct in-house quality
test, drop test with Sitcom
QC/Agent
Passed

Failed

Checked
by Sitcom
PD

Vendor send samples for
MTL test if required by
Sitcom

Approved

Passed
Sitcom QC/Agent to take pictures,
document then send to Sitcom PD for
approval

Passed

End



Checked by
Sitcom PD

Approved

4

Not
Approved

QC Manual


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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
_____________________________________________________________________________________________________________

1.3 Color Panel Development Process Flow
Vendor needs to submit 12 pcs of color panel size 10”x10”for Sitcom PD to approve.
Approved color panel will be filled information below on the back of panel
‰ Code of color (Track from PSA form)
‰ Vendor name
‰ Material of subtrate
‰ Level of sheen
‰ Collection
‰ Signature and name of approval
‰ Date of signing
‰ Number of color panel signed
After signing Approved color panels, 6 pcs of color panel will be returned to vendor. Sitcom
will keep 6 pcs, 4 pcs for Sitcom local office/Agent for QC’s inspection using and 2 for Sitcom
PD. Vendor will use approved color panel during the finish process. During the production
process, vendor needs to check product before and after each steps of finishing to assure all
required steps and coating application are followed in manufacturing process.
Vendor prepare 12 pcs 10”x10”
for Sitcom review

Sitcom PD or QC to
review (color,
sheen, adhesion,
Pencil hardness)

Sitcom to sign Approved color
panel. 6 pcs will be kept by vendor,
4 pcs kept by Sitcom local
office/Agent, 2 pcs kept by PD

Vendor and Sitcom QC use color
panel to check product during
finishing process.



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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
_____________________________________________________________________________________________________________

CHAPTER 2

INSPECTION PROCEDURE
2.1 Inline inspection
The In-line inspection is used to monitor the quality of the product through the production
rough mill, machining, assembling stages and finishing stages until the beginning of the
packing stage.
2.1.1 Preparation documents for inline inspection
To conduct one inline inspection, Sitcom QC need to have and study the below
‰ Master sample signed
‰ Approval color panel
‰ Document of master sample signed with photos
‰ Document of approval inhouse packing drop test during sample development stage.
‰ Document of approval inhouse quality test
‰ Sitcom PSA sheet
‰ MTL packing test if product is required
‰ MTL quality test if product is required
‰ Defect Classification List document
‰ Measuring tape
‰ Drawing if possible.
‰ Camera
2.1.2 Inspection Schedule
To schedule and arrange in-line inspections properly and effectively, the QC Manager must be
kept well informed of the progress of the mass-production. The sitcom office staff need to
work with vendor on the approximate completion dates for the manufacturing of the P.O and
pass to the QC Manager to plan the inspection schedule. Any changes in production schedules
the office staff should inform QC Manager so that QA inspection schedules can be adjusted
accordingly.
During inspection time in the factory QC inspector can be required to update actual production
status, any quality problems or any jeopardy that affect to shipment point for Sitcom office
staff.
The frequency of the In-line inspection will depend upon the type of product being produced,

the production quality as perceived, the vendor’s past performance and the order quantity.
2.1.3 Procedure
The In-line inspection includes checking the raw material’s quality, construction,
measurement, color, labels, hardware, tags, carton printing, workmanship, with special



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attention to finish, paint, sheen, durability and instructions. If QC found any problems or
discrepancies they must bring to the attention of the vendor management so that action can be
taken to correct the problem or discrepancies. A inspection report should be completed every
time an In-line inspection is performed at a factory. All information are recorded in the
inspection report must be explained in verbal by Sitcom QC to factory representatives. All
problems, defects and discrepancies that need to be improved, corrected must be noted in the
report. After reviewing, the factory management should sign the report indicating full
understanding and agreement to rectify the discrepancies as discussed. If the factory
management disagrees with the findings, they can comment the points they do not agree with.
However, the factory management must sign the report.
In the case of any serious issues found by QC, The Sitcom QC Manager must be informed
immediately to support. If one serious issue found that jeopardise to shipment point QC
inspector should also inform Sitcom Sourcing/ Merchandise manager.

During inline inspection Sitcom QC should walk along the production line to review the
production (or components) for the following:
a) Material Quality and colors.
b) Moisture content
c) Assembling check
d) Accuracy of design, construction against the approval sample and all notes on approval
sample.
e) Workmanship.
f) Measurement. (where possible)
g) Color
h) Sheen
i) Carton printing
j) Packing material
k) Hardware
with the focus as below
‰ At the rough mill ( Cutting, sawing, planning, glueing…) stage: Verify what is
material used, quality of material, MC for Key components
‰ At the machining (drilling, shaping, routering…) stage: measure dimensions, MC,
the accuracy of angle, square… for the key components
‰ Assembling stage: Assembly 3 products. QC should ask factory to use correct
hardware if available. Verify step by step with Assembly Instruction, check
construction is stable after test or not, check operation components can work
smoothly, MC... conduct interchange test with old item if it is a resourced item.
‰ Sanding stage: Check smooth of surface, focus to sanding marks, glue marks, all
edges should be sanded 1.5mm radius or follow the note on Master Sample if
specified.
‰ Finishing stage: verify color, sheen against with approval color panel. Sitcom QC
should compare all components in the product for matching for example the legs
should be compare with frame, top, drawer… for color match and sheen. Quantity
of inspection should be at least 3 pcs for each key components

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‰

Preparation before packing: verify carton layout, PO sticker, hardware bag/blister
bag, hardware sticker, desicant bag, law label, packing material and way of
packing.



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Summaried table for inline inspection
Stage
Inspection Points
Rough
Mill
( Material used, quality
Cutting, sawing, material, MC
planning,
glueing…) Stage

Criteria
of Verify material with master
sample. Reject non-conforming
materials; for example, dead
knots, blue stain, water mark,
sap gum of wood, and other
wood defects. MC must be
<=12%. Prefer within 8-12%
Machining
Measure dimensions, MC, the MC must be <=12%. Prefer
(drilling, shaping, accuracy of angle, square… for within 8-12%
routering…) stage: the key components
Assembling stage
‰ Verify step by step with ‰ Approved
Assembly
Assembly Instruction.
instruction
‰ Construction
‰ Must be stable

‰ Operation
components, ‰ Must operate smoothly
hardware.
‰ MC must be
<=12%.
‰ MC...
Prefer within 8-12%
‰ Interchange test
‰ Interchange assemble with
old items.
Sanding stage
A,
B
surfaces,
joints, Must be smooth. No sanding
grooves…
marks, glue marks accepted. All
edges should be sanded 1.5mm
radius or follow the note on
Master Sample.
Finishing stage
Matching color, sheen.
Approved color panel.
All components in the product
should mtach color and gloss
for example the legs should be
compare with frame, top,
drawer… for color match and
sheen.
Preparation before ‰ Carton layout, PO sticker, ‰ Approved carton layout.

packing
hardware bag/blister bag,
Sitcom
standard
for
hardware sticker, desicant
hardware bag, sticker,
bag, law label
desicant, law label
‰ Packing material and way ‰ MTL packing test or
of packing
inhouse drop test report

Sampling Plan
3 pcs for each
key
components

3 pcs for each
key
components
Assembly
3
products. QC
should factory
to get correct
hardware
if
available.

3 pcs for each
key
components

At least 3 pcs
for each key
components

At least 3 pcs.

2.1.4 In-line inspection report distribution
Copy of the Inline Inspection Reports must be sent to factory right after vendor represantative
signed. Full inline inspection report with attached photos is expected to fullfill by Sitcom QC
within latest one working day after inspection date and to send to Sitcom QC manager for
review. Sitcom office staff will send QC inline inspection report to Sitcom US.


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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
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2.2 Final Inspection
The Final Inspection consist several of inspection to ensure quality is meeting with standard
and product can be shipped.

2.2.1 Preparation documents for final inspection
To conduct one Final Inspection, Sitcom QC need to have and study the below
‰ Master sample signed. Vendor need to bring master sample to inspection area for
Sitcom QC to verify.
‰ Approval color panel
‰ Document of master sample signed with photos
‰ Document of approval inhouse packing drop test during sample development stage.
‰ Document of approval inhouse quality test
‰ Sitcom PSA sheet
‰ MTL packing test if product is required
‰ MTL quality test if product is required
‰ Defect Classification List document
‰ Measuring tape
‰ Drawing if possible.
‰ Camera
2.2.2 Inspection Schedule
To schedule and arrange Final-line inspections properly and effectively, the QC Manager must
be kept well informed of the progress of the mass-production. The sitcom office staff need to
work with vendor on the approximate completion dates for the manufacturing of the P.O and
pass to the QC Manager to plan the inspection schedule. Any changes in production schedules
the office staff should inform QC Manager so that QA inspection schedules can be adjusted
accordingly.
During inspection time in the factory QC inspector can be required to update actual production
status, any quality problems or any jeopardy that affect to shipment point for Sitcom office
staff.
Each separate shipment and SKU will require a Final Inspection conducted by a Sitcom/Agent
QC Inspector.
2.2.3 Procedure
The inspection is focused into parts
2.2.3.1 Packaging Check

Sitcom QC should start packing check at the starting time of packing line. This consists of
checking the following:



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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
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a) Size and Construction of Carton being used.
b) Carton Marking.
c) Packing material, component shimmed, secured correctly follow MTL report or inhouse
drop test report.
It’s always at least 3 cartons should be unpacked randomly. Vendor should be asked to hold for
rechecking if one or more cartons are found with packaging mistakes.
2.2.3.2 Color Check
Color check is already done in the inline inspection but QC inspector should again check color,
sheen compare with approved color panel. At least 3 finished products should be brought to the
light area to check color matching. Notice color matching within one product and also within
the collection. If chairs, table, dresser are parts of a collection we should be compared color
matching.
2.2.3.3 Assembly Test
This test is only applicable to Knock Down (KD) items. The test-sampling plan should be at
least 3 pcs. Generally, for any lot size, 3 samples are selected, all of which must pass the test in

order for the shipment to be passed. The inspector should assemble the furniture unit in
accordance with the Assembly Instruction sheet enclosed with the package, using the tools in
hardaware bag to assemble.
The following will result in automatic failure: - - The knock down components cannot be
assembled/do not fit together. - Missing parts, hardware, screws, specified special assembly
tools, etc. - The assembled item cannot function as intended, e.g. drawers cannot move, doors
cannot be opened, table/chair not level, etc. - Mistakes in the assembly instructions, improper
use of language/missing language (if multi-lingual). If the test result is ‘failed’, the shipment
cannot be released.
2.2.3.4 Drop Test
Only the first shipment is required drop test. In the case packing material is suspicious to have
discrepancies that tools to check that is not available in factory then Sitcom QC can require
inhouse drop test to verify packing.
Drop test quantity is done for one carton only but any fails, the shipment cannot be released.
vendor needs to improve packing to pass drop test before shipment.
2.2.3.5 Workmanship Check
The inspector will use some kinds of sampling plans below for workmanship check



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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
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Sampling Plan
100%

How
When
Sitcom QC check one by ‰ First shipment at new vendors
one product before putting ‰ Products have quality issue in the past
shipments.
into carton
‰ Replacement orders
DUP
(During At least 70% quantity of ‰ Normal first shipment at old vendor.
Packing
line) product randomly checked ‰ When Sitcom QC available at the
level
by Sitcom QC before
packing time it prefers to apply this
putting into carton.
for repeat orders than AQL level
AQL 4.0 L1 ( Use AQL table below to At least 80% of the shipment lot has been
MIL-STD-105E) determine the quantity of packed and the balance cleared from the
sample.
The
selected production lines.
samples
should
be
representative of the total
shipment.

AQL 4.0 level 1 MIL-STD 105E table

Lot Size (shipment size)

Level 1
(AQL 4.0)
Sample size
(Inspected qty)

Accept

Reject

2_90

3

0

1

91_280

13

1

2

281_500

20

2

3

501_1200

32

3

4

1201_3200
50
5
6
The parts listed below is also listed out in the final inspection report should be followed for
every inspection so that no part of the operation is overlooked.
a) Material defects
b) Construction defects
c) Finishing defects
d) Color, sheen check: compare with approved color panel and checking color match between
parts in one product and in one lot.
e) Upholstery defects
f) Handling defects
g) Hardware defects
h) Functional defects

2.2.3.6 Identify the Defects
During the quality check, the position of all major and minor defects should be marked using a
adhesive red arrow sticker. The QA Inspector should also make a note of the type of defect
found, to be used when compiling the inspection report at the end of the evaluation process.



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The items with major defects should be put to one side. Once inspection of the sample lot has
been completed, the total number of defective units should be recorded in the appropriate box
provided on the Final Inspection report form. This figure will determine whether the goods can
be accepted or rejected against the inspection plan being used.
2.2.3.7 Final inspection report distribution
Copy of the Final Inspection reports must be sent to factory right after vendor represantative
signed. Full Final Inspection report with attached photos is expected to fullfill by Sitcom QC
within latest one working day after inspection date and to send to Sitcom QC manager for
review. Sitcom office staff will send QC Final Inspection report to Sitcom US.



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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
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CHAPTER 3
QC INSPECTOR’S RESPONSIBILITY
3.1 Escalation Of Problems In a Direct Sitcom Factory
Below chart will instruct Sitcom QC which quality problem level should raised to which level
on Sitcom side and factory side
Sitcom Side
Sitcom QC Inspector

Problems

Factory Side

Minor Problems

Line Supervisor

Major Problems
Major Problems
Critical Problems
Production Manager
Critical Problems

QC Manager

Critical Problems

Factory Manager/
Owner

Critical Problems

PD Manager

3.2 Escalation Of Problems In An Indirect Sitcom Factory
If Sitcom uses an agent, Sitcom QC should advise all problems noted to the Agent’s QC
personnel and to the Agent’s QC supervisor. Problems noted will be communicated by the
Agent QC supervisor to the Factory personnel. Sitcom personnel should not discuss quality
problems directly with the Factory personnel. If the Agent QC are not present, the Agent
QC supervisor should be called.
The process for quality disagreements is as follows:
Sitcom QC addresses with Agent QC, if Agent QC disagrees, address to Agent QC
Supervisor



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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
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If Agent QC Supervisor disagrees, address with Sitcom QC manager. If Sitcom QC
manager does not waive, address to Sitcom Corporate PD Manager
At all times, Sitcom personnel should maintain a positive and proactive relationship with
the Agent and Factory personnel
Sitcom QC address with Agent
QC inspector

Agreed

Agent QC inspector works
with factory

Agreed

Agent QC
supervisor/Manager works
with factory

Disagreed

Sitcom QC address with Agent
QC supervisor/Manager
Disagreed

Agreed
Sitcom QC Manager address

with Agent QC /supervisor
Manager
Agreed

Sitcom QC address with
Sitcom QC Manager

Sitcom QC Manager address
with PD Manager
3.3 Quality Control Inspector Job Description
3.3.1 Purpose of Position
‰

To inspect clients’ product prior to shipment to ensure that the quality control standards,
client’s specifications, carton markings, documentation, labeling and packaging have all
been correctly adhered to.

‰

To regularly report any irregularities and monitor any shipments being held pending the
correction of discrepancies, ensuring that the Sitcom or sitcom’s client quality
expectations are met.

3.3.2 Scope
The QCI is responsible for conducting quality control programs for Sitcom primarily for, but
not limited to, inspections in their designated areas.



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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
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3.3.3 Duties and Responsibilities
‰

To personally visually examine adequate product sample lots prior to shipment to
ensure that Sitcom specifications and standards have been adhered to, and to ensure that
the general appearance of the product is acceptable.

‰

To ensure that product is correctly sorted, labeled and packaged, and that the cartons are
properly marked, exhibiting the correct destination, department and article number.

‰

To prepare inspection reports for all product inspected, for both in-line and final
inspections, and submit the reports to the QC Manager.

‰

To submit inspection records for in-line and final inspections to the QC Manager on
time.

‰

To conduct inhouse quality test and inhouse drop test and record the test when required.

‰

To prepare monthly and quarterly reports as directed by the QC Manager.

‰

To maintain QC file, product doc, approval color panel… in good condition, and easy
for using

‰

To check upon the implementation of corrective action plan and report to QC manager.

‰

Liaise with Sitcom Sourcing/Merchandise as required on production status and report
them immediately any potential shipment delays.

‰

Completed and submit weekly as required the actual production status at each incharged
vendor.

‰

To provide the QC Manager with recommendations for improvement.

3.3.4 Knowledge and Skills Required
‰

Have at least three to five years’ related experience in furniture. Technical
qualifications are desirable.

‰

Know general product quality standards, statistical sampling, packaging, labeling and
carton marking requirements.

‰

English language capability is expected but not a must

‰

Effective communication skills and have the ability to work and interact with other.

‰

Be able to work independently with minimum supervision.



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3.3.5 QC Peformance
QC inspectors will be evaluated quarterly which include an assessment of
Completeness of documentation on time
‰

Attendance: Faithfulness in coming in to work daily and conforming to scheduled
work hours.

‰

Familiarity with Sitcom procedures

‰

QC record from PC comments, claim value

‰

Reliability - The extent to which the employee can be depended upon to be available
for work, do it properly, and complete it on time. The degree to which the employee is
reliable, trustworthy and persistent.

‰

Judgment - The extent to which the employee makes sound decisions. Ability to base
decisions on fact rather than emotion.

‰

Factory cooperation and internal cooperation: Willingness to work harmoniously with
others in getting a job done. Readiness to respond positively to instructions and
procedures.

‰

Quantity of Work - Work output of the employee.

‰

Initiative and Creativity - The ability to plan work and to go ahead with a task without
being told every detail, and the ability to make constructive suggestions.



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CHAPTER 4
DOCUMENT SUPPLEMENTARY TO INSPECTION
4.1 Inspection form
FURNITURE INLINE AUDIT REPORT
Date:
Factory:
Sitcom PO#

Client PO#

Operation

Item/SKU #

Description

Qty

Workmanships/comments

Rough mill
(cutting, planning, gluing/pressing).
Randomly check on 5 components.
Measure MC for main components.
(MC should be 8-12 for indoor
furniture)

Machining
Measure dimension, position of

drilling holes,…Randomly check 5 pcs
of main components.

Assembly
Assemble 3 products: check stability?
Moving components operate
smoothly? No gap at joints? Easily
assembly? dimension is correct? MC
check and write down MC range

Sanding before finishing
Smooth? No oversanding? Edge
should be with 2mm radius? No glue
mark?

Finishing

Master color panel #:

Signed by:

Date:

Check at least 5 pcs with master color
panel. Compare color on all
components to match together (color
on drawer, top, leg,…)

Verify pre-packing
(carton lay out, law label, care

instruction, AI, hardware, hardware
bag/ blister-pack, PO sticker)

Overall comments and disposition

Sitcom Inspector
Signature

Name (

Agent/Factory
Signature

)



Name (

18

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Final Inspection Report
Report No:
850

42 nd Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:

Ins Date:

Cust:Sitcom

Sitcom PO#

Cust's PO#

Vendor:

Item/Sku#

Approved sample dd:

Factory:

Signed by:

Defect

Qty
(PCS)

Description

MJ

First

Inspect
ed
level:
AQL4.0
L1; Inspect
100%, ed Qty
(PCS)
Dup.

Refinal 1

Qty

Found

Ac

Re

Approved color chip dd:
Mn

W2-Insect Infestation

F1-Color does not match the color chip

F2-Distressing and overall aesthetic does not match
approved sample and color chip

W3-Knot split (less than 1 inch)

F3-Finish application uneven/inconsistent

&

W4-Knot split (greater than 1 inch)

M
A
T
E
R
I
A
L

W5-MC outside specified range(indoor furniture>12%)

F4-Bubles dried into finish
F5-Shading within unit(color or gloss level is inconsistent
within single unit)

W6-Mold or mildew

F6-Shading among lot(color or gloss level is inconsistent
among other units in lot)

W7-Offensive odor

F7-Color or gloss level outside approved shade band

W8-Split wood

F8-Cracked finish

Others
C1-Drawers not even/level
C2-Loose dowels
C3-Wrong dowel type(too short, too long, not groove,.
C4-Dovetail joints chipped,cracked, etc

C
O
N
S
T
U
C
T
I
O
N

F13-Blushing (cloudy finish)
F14-Orange peel surface texture

F16-Pinholes
F17-Bad finish repair
F18-Resin bleed-through(ex:yellow knot show white
finish)

13

1

2

3

20

2

3

3

501_1200

32

3

4

3

1201_3200

50

5

6

3

MJ

D1-Chipped finish/wood(less than 1/8")

D
A
M
A
G
E

D6-Surface scratch that penetrates to subtrate

D2-Chipped finish/wood(greater than 1/8")
D3-Ding/dent (finish not broken, diameter 1/8" or
less)
D4-Ding/dent (finish not broken, diameter greater
than 1/8")
D5-Surface scratch that does not penetrate

subtrate

D7-Gouge(breaks/penetrates wood fiber)
D8-Soil/marks(not removable without using
cleaning solution, includes residue from tape)
Others

H1-Corrosion
H2-Damage(ex: bent, scratched, broken)

H
A
R
D
W
A
R
E

H3-Install too closed to edge
H4-Install unevenly
H5-Loose or stripped(included screw)
H6-Not as approved
H7-Sharp point/edge
H8-Tools provided do not perform as intendedeasy bent or stripped.

F19-Rough surface texture

H9- Missing hardware

C10-Joint failure

F20-Permanent finger prints in finish (not removable)

Others

C11-Joint gapped
C12-Joint expansion/contraction(ex: raw wood
becomes visible due to wood movement)

F21-Overwhelming odor not consistent with normal smell
Others

C13-Not square(ex: joints, panels, cases)

U1-Open seam
U2-Skewed or crooked seam, not straight, bowed
U3-Skipped stich

C16- Unstable(ex: case wobbly or loose)

U4-Broken stich

C17-Unstable and could result in collapse or injury

U5-Hole/tear in fabric

C18-Bad wood repair(ex: excessive putty/glue,sloppy
wood plug,…)

U6-Pile crushed(velvet)

A2-Assembled unit stability posing safety issue
A3-Difficult to assemble
A4-Can not assemble
A5-Instructions inadequate/incomplete
A6-Instructions incomplete (potentially making it
impossible to assemble)
A7-blurred or unclear printed assembly instructionhard to read

F
U
N
C
T
I
O
N

O1-Component doesn't operate smoothly(door,
drawer,..)
O2- Item not level
O3-Levelers do not function as intended
O4-Unstable on level surface (i.e wobbly, loose,
not structurally sound)
O5-Unstable to the point it could result in
collapse or injury
Others
P1-Corner protection inadequate

U7-Wrong nap direction(in case of napped/brushed
fabrics)
U8-Scratch/abrasion marks
U9-Soil
U10-Exposed staples (no sharp point)

P
A
C
K
A
G
I
N
G

U11-Esposed staple (sharp point)

A8-Missing or illegibal assembly Instructions
A9-Missing components

U16-Color or gloss level outside approved shade band

A10-Missing hardware(can not assemble)

U17-Missing/incorrect label(ex: law label)

A11-Missing extra hardware but can assemble

U18-Chatter marks on leather

A12-AI or care instruction missing language required

Others

P2- Drop test failed
P3-hardware packets not adequately secured
P4-Hardware packet do not have red ribbon
indicators
P5-Actual packaging not consistent with MTL
tested report
P6-Inconsistent packaging(unit to units)
Others

U12-Upholstery construction and padding are not
consistent with specs/ approved sample
U13-Upholstery fabric or leather too loose
U14-Shading within unit(color or gloss level is
inconsistent within single unit)
U15-Shading among lot(color or gloss level is
inconsistent among other units in lot)

C
A
R
T
O
N

M

A
R
K
I
N
G

M1-Carton sequencing missing
M2-Carton warning(when required by law)
missing
M3-Country of origin on master carton missing or
incorrect
M4-Master carton label missing
M5-SKU# or PO# missing or incorrect.
M6-Price ticket(when required) missing or
incorrect
M7-Mis-spelling on master carton label
Others

Assembling Qty:

Actual MC range:

Others

3

281_500

C9-Wrong joint type

U
P
H
O
L
S
T
E
R
Y

1

H
A
N
D
L
I
N
G

F12-Excess finish on floor contact surface?

C7-Insufficient glue

C14- Sharp edge/corners(sharp, broken edge,
splinters,…)
C15- Sharp point(exposed nails or protrusion of nail

head,...)

Re
0

Defect

Mn

F11-U and V groove not clean/smooth

C6-Excessive glue

A1-Assembled unit unstable but does not pose a
safety issue

A
S
S
E
M
B
L
Y

F9-Debris dried into finish

F15-Overspray (ex: onto hardware or adjacent panel,...)

C8-Glue not as specified(Includes wrong glue type)

91_280

Ac

3

F10-Drips/Finish build up

C5-Delamination (adge band/veneer separation, etc.)

Others

F
I
N
A
L

F
I
N
I
S
H
I
N
G

Passe

d Qty
Passe
d
Major Minor
Failed (pcs)

MJ

W
O
O
D

W9-Warped(includes bow, twist,crook diamond and
cup with >3mm/meter)

Inspect

2_90

Result

Signed by:

Defect

W1-Hole or material (Not consistent with
specs/approval sample)

Min

Assembled
Qty
required

Level 1
(AQL 4.0)

Refinal 2

Overall Comments and Disposition:

Inspector
Signature

Factory representative
Signature

Name (

)



Name (

19

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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
_____________________________________________________________________________________________________________

4.2 Defect Classification List

FURNITURE DEFECT CLASSIFICATION LIST
(Rev: Feb 08)

I. DETERMINATION OF DEFECTS

Critical Defect (C)
- AQL = 0.0 (1 critical defect = failed audit, regardless of location on item)
- Hazardous or unsafe for consumer use.
- Violation of any U.S. regulation. Items can not be sold due to condition.

Major Defect (MJ)
Major Defect is likely to result in failure, or to reduce the functionality of the product for its intended
purpose. If number of major
defective units found is equal or greater than the allowable limit follow AQL table, the
audit will be result in failure.
Major defect will be result in product cannot be sold as First
Quality.
Major defect will be result in customer reject or returning product.
Major defects will be included but not limited to the following

‰

Negatively affects appearance, durability, or performance of item.

‰

Non-compliance with specification or approval sample.

Minor Defect (mn)
- Meets definition of Major Defect, but does not significantly compromise appearance, durability, or
performance of item.
- Three or more Minors in same zone are scored as single Major Defect.
Do not Score (0)
- Has no impact on appearance, durability, or performance of item.

ZONE KEY (corresponds to Defect Location Guide)
Zone A = Visual surface (always in view by user during normal use)
Zone B = Secondary visual surface (occasionally in view or can be touched by user during normal
use)
Zone C = Not visual surface (rarely in view by user)
One defect can be major when it's in zone A but it can be minor defect if it appear in Zone B or C.
Refer to below table for detail.



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_____________________________________________________________________________________________________________

Product Category: WOOD FURNITURE
2. DEFECT CLASSIFICATION AND SCORING OF DEFECTS

Location / Zone

Defect
code

A

B

C

Hole or material (not consistent with specs/approval sample)

W1

MJ

MJ

MJ

Insect infestation

W2

C

C

C

Knot split, if knots are specified (1 inch or less)

W3

mn

mn

0

Knot split (greater than 1 inch)

W4

MJ

MJ

mn

Moisture content outside specified range (indoor >12%)

W5

MJ

MJ

MJ

Mold or mildew

W6

C

C

C

Offensive odor

W7

MJ

MJ

MJ

W8

MJ

MJ

mn

W9

MJ

MJ

mn

Drawers not even/level

C1

MJ

MJ

0

Loose dowels

C2

MJ

MJ

mn

Wrong dowel type(too short, too long, not groove,.)

C3

MJ

MJ

mn

Dovetail joints chipped,cracked, etc

C4

MJ

MJ

mn

Delamination (edge band/veneer separation, etc.)

C5

MJ

MJ

mn

Excessive glue

C6

MJ

mn

0

C7

MJ

mn

mn

C8

MJ

MJ

MJ

Wrong joint type

C9

MJ

MJ

MJ

Joint failure

C10

MJ

MJ

MJ

C11

MJ

mn

0

C12

MJ

mn

0

Not square(ex: joints, panels, cases)

C13

MJ

MJ

0

Sharp edge/corners(sharp, broken edge, splinters,…)

C14

MJ

MJ

mn

Sharp point(exposed nails or protrusion of nail head,...)

C15

C

C

MJ

Unstable(ex: case wobbly or loose)

C16

MJ

MJ

mn

Unstable and could result in collapse or injury

C17

C

C

C

Bad wood repair(ex: excessive putty/glue,sloppy wood plug,…)

C18

MJ

MJ

mn

1. WOOD

Split wood
Warped (includes bow, crook, twist, diamond, or cup with
>3mm/meter)

2. CONSTRUCTION

Insufficient glue
Glue failure, or glue used was not as specified(Includes wrong
glue type)

Joint gapped
Joint expansion/contraction(ex: raw wood becomes visible due to
wood movement)

3. FINISH



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_____________________________________________________________________________________________________________

F1

MJ

MJ

0

F2

MJ

MJ

0

F3

MJ

mn

0

F4

MJ

mn

0

F5

MJ

mn

0

F6

MJ

mn

0

Color or gloss level outside approved color chip

F7

MJ

MJ

0

Cracked finish (along joints or panel surface)

F8

MJ

mn

0

Debris dried into finish (dust, leaves,hair... dried into finish)

F9

MJ

mn

0

Drips/Finish build up

F10

MJ

mn

0

U and V groove not clean/smooth

F11

MJ

mn

0

Excess finish on floor contact surface?

F12

mn

mn

mn

Blushing (cloudy finish)

F13

MJ

mn

0

Orange peel surface texture

F14

MJ

mn

0

Overspray (ex: onto hardware or adjacent panel,...)

F15

MJ

mn

0

Pinholes

F16

MJ

mn

0

Bad finish repair

F17

MJ

mn

0

Resin bleed-through(ex:yellow knot show white finish)

F18

MJ

mn

0

Rough surface texture

F19

MJ

mn

0

Permanent finger prints in finish (not removable)

F20

MJ

mn

0

Overwhelming odor not consistent with normal smell

F21

MJ

MJ

MJ

Open seam

U1

MJ

MJ

mn

Skewed or crooked seam, not straight, bowed

U2

MJ

mn

0

Skipped stich

U3

MJ

mn

mn

Broken stich

U4

MJ

mn

mn

Hole/tear in fabric

U5

MJ

MJ

MJ

Pile crushed(velvet)

U6

MJ

mn

0

Wrong nap direction(in case of napped/brushed fabrics)

U7

MJ

MJ

0

Scratch/abrasion marks

U8

MJ

mn

0

Soil

U9

MJ

mn

0

Exposed staples (no sharp point)

U10

MJ

MJ

0

Esposed staple (sharp point)

U11

MJ

MJ

MJ

Color does not match the color chip
Distressing and overall aesthetic does not match approved
sample and color chip
Finish application uneven/inconsistent
Bubles dried into finish
Shading within unit(color or gloss level is inconsistent within
single unit)
Shading among lot(color or gloss level is inconsistent among
other units in lot)

4. UPHOLSTERY



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850 42 Avenue, Oakland CA 94601 P: 510.434.1600 F: 510.434.1601 E:
_____________________________________________________________________________________________________________

Upholstery construction and padding are not consistent with
specs/ approved sample

U12

MJ

mn

mn

U13

MJ

MJ

mn

U14

MJ

mn

0

U15

MJ

mn

0

Color or gloss level outside approved shade band

U16

MJ

mn

0

Missing/incorrect label(ex: law label)

U17

MJ

MJ

MJ

Chatter marks on leather

U18

MJ

mn

0

Chipped finish/wood (less than 1/8")

D1

mn

mn

0

Chipped finish/wood (greater than 1/8")

D2

MJ

mn

0

Ding/dent (finish not broken, diameter 1/8" or less)

D3

mn

mn

0

Ding/dent (finish not broken, diameter greater than 1/8")

D4

MJ

mn

0

Surface scratch that does not penetrate subtrate

D5

MJ

mn

0

Surface scratch that penetrates to subtrate

D6

MJ

MJ

0

D7

MJ

MJ

mn

D8

MJ

mn

mn

Corrosion

H1

MJ

MJ

MJ

Damage(ex: bent, scratched, broken)

H2

MJ

MJ

MJ

Install too closed to edge

H3

MJ

MJ

MJ

Install unevenly

H4

MJ

MJ

0

Loose or stripped(included screw)

H5

MJ

MJ

MJ

Not as approved

H6

MJ

MJ

MJ

Sharp point/edge

H7

MJ

MJ

MJ

Tools provided do not perform as intended-easy bent or stripped.

H8

MJ

MJ

MJ

Missing hardware

H9

MJ

MJ

MJ

Component doesn't operate smoothly(door, drawer,..)

O1

MJ

MJ

MJ

Item not level

O2

MJ

MJ

MJ

O3

MJ

MJ

MJ

O4

MJ

MJ

MJ

Upholstery fabric or leather too loose
Shading within unit(color or gloss level is inconsistent within
single unit)
Shading among lot(color or gloss level is inconsistent among
other units in lot)

5. HANDLING DAMAGE

Gouge(breaks/penetrates wood fiber)
Soil/marks(not removable without using cleaning solution,
includes residue from tape)

6. HARDWARE

7. FUNCTION (OPERATION)

Levelers do not function as intended
Unstable on level surface (i.e wobbly, loose, not structurally
sound)



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_____________________________________________________________________________________________________________

Unstable to the point it could result in collapse or injury

O5

C

C

C

Assembled unit unstable but does not pose a safety issue

A1

MJ

MJ

MJ

Assembled unit stability posing safety issue

A2

C

C

C

Difficult to assemble

A3

MJ

MJ

MJ

Can not assemble

A4

C

C

C

A5

MJ

MJ

MJ

A6

MJ

MJ

MJ

blurred or unclear printed assembly instruction-hard to read

A7

mn

mn

mn

Missing or illegibal assembly Instructions

A8

MJ

MJ

MJ

Missing components

A9

MJ

MJ

MJ

Missing hardware(can not assemble)

A10

C

C

C

Missing extra hardware but can assemble

A11

MJ

MJ

MJ

AI or care instruction missing language required

A12

MJ

MJ

MJ

Corner protection inadequate

P1

MJ

MJ

MJ

Drop test failed

P2

C

C

C

P3

mn

mn

mn

P4

MJ

MJ

MJ

Actual packaging not consistent with MTL tested report

P5

MJ

MJ

MJ

Inconsistent packaging(unit to units)

P6

MJ

MJ

MJ

Carton sequencing missing(when required)

M1

MJ

MJ

MJ

Carton warning(when required by law) missing

M2

C

C

C

Country of origin on master carton missing or incorrect

M3

MJ

MJ

MJ

Master carton label missing

M4

MJ

MJ

MJ

SKU# or PO# missing or incorrect.

M5

MJ

MJ

MJ

Price ticket(when required) missing or incorrect

M6

MJ

MJ

MJ

Mis-spelling on master carton label

M7

MJ

MJ

MJ

8. FINAL ASSEMBLY INSPECTION

Instructions inadequate/incomplete
Instructions incomplete (potentially making it impossible to
assemble)

9. PACKAGING

hardware packets not adequately secured
Hardware packet do not have red ribbon indicators(when

required)

10.CARTON MARKING

4.3 Defect location guide



24

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DEFECT LOCATION GUIDE
FURNITURE
Rev: Feb 08