【117】12 Quality Control Hurdles: Every Product Takes the Challenge

【117】12 Quality Control Hurdles: Every Product Takes the Challenge

Last week, BYD's audit team visited our factory with a special request: to randomly select a car door handle currently in production and track its entire quality inspection journey. From 9 a.m. to 5 p.m., this product traveled 900 meters through the workshop, undergoing 12 inspection processes and generating 17 inspection reports.

The first hurdle is at raw material warehousing. After scanning to confirm the batch, samplers take material from six positions in the same batch and send it to the testing lab for melt index, ash content, and moisture content tests. The second hurdle is at the injection molding machine. After the robotic arm removes the product, an infrared thermal imager immediately scans the surface temperature distribution; any uneven cooling is marked. The third hurdle is at the first-piece inspection station, where the probe of a three-coordinate measuring instrument collects data from 128 points on the product surface, which is then compared with a digital model.

What impressed most was the seventh hurdle—simulated assembly testing. Our fixtures simulate assembly actions on the production line 20 times at different angles and forces. BYD engineers operated them personally and found that our fixtures were more stringent than their factory's testing equipment. \"You're really making things difficult for yourselves,\" he joked half-heartedly, \"With such high standards, isn't the pass rate under pressure?\"

The pressure is indeed huge. But we are even clearer that if problems arise after the product reaches the customer, that pressure is truly unbearable. Last year, when producing 5G base station radomes for Huawei, adding an X-ray flaw detection test discovered internal 0.1mm pores, preventing potential failure of an entire batch of products. Huawei's quality engineer said, \"These pores won't be exposed in short-term tests, but after five years of sun and rain outdoors, they might become the starting point for cracking.\"

Why 12? This number wasn't decided on a whim. Each process corresponds to a mistake we've made or a problem customers have complained about. For example, the salt spray test at the 10th hurdle was established because a batch of products exported to Europe three years ago rusted in coastal areas; the drop test at the 11th hurdle was added due to feedback from a robotic vacuum cleaner customer about product damage during transportation.

Every hurdle has a story. The coordinate measuring machine was purchased three years ago. At the time, to measure the precision of a 0.05mm hole diameter, we approached three external testing agencies, but their data didn't match. The founder made an on-the-spot decision: \"We'll buy our own and set our own standards.\" This machine later became our \"factory treasure,\" not only serving us but also providing testing services to more than a dozen small surrounding enterprises.

Now, these 12 hurdles safeguard over 50,000 products daily. Some employees joke that our products are harder than the college entrance exam—they need to pass 12 hurdles to \"graduate.\" And we know that it is precisely this strict graduation standard that has earned Fuying's products a reputation for \"exemption from inspection\" in the market.

Let every product undergo a rigorous graduation exam—the 12 Quality Control Hurdles of Fuying safeguard the promise of zero defects.