Quality Assurance
Quality Isn’t an Inspection — It’s a System
At Fulei Metal, quality is not a checkpoint at the end of production. It is a system that starts when raw material enters our gate and ends only when the customer confirms their parts are correct. Every step in between is documented, measured, and traceable.
We operate a dedicated inspection room separate from the production floor, equipped with CMM, spectrometer, salt spray chamber, and precision gauges. Every production run follows a quality plan approved before manufacturing begins. Every part carries a traceability code linking it to material lot, machine, operator, and inspection record.
This is why global brands like Hog Slat (USA), CNClib (Korea), and UK industrial clients trust us with their manufacturing — and why we can provide full documentation with every shipment.
Our Quality Lab
A separate, climate-controlled room dedicated to measurement and testing — not a corner of the production floor.
Most sheet metal shops in China do not have a dedicated inspection room. They check parts on the production floor, next to running machines, dust, and temperature fluctuations. We built a separate room because measurement accuracy depends on environment control.
Our inspection room is temperature-controlled at 20°C ± 2°C, dust-filtered, and vibration-isolated. All precision measurement happens here — CMM probing, surface roughness checks, height gauge verification, and go/no-go gauge confirmation.
5-Stage Inspection — At Every Critical Point
Inspection does not happen only at the end. It happens at five defined gates, each with specific tools, acceptance criteria, and documentation.
IQC — Incoming Quality Control
- Verify Material Test Certificate (MTC) from supplier against purchase order specification
- Spectrometer analysis to confirm material composition (Cr, Ni, C, Mn, Si, etc.)
- Thickness verification with micrometer at 5 points per sheet (tolerance ±0.05mm)
- Visual inspection for surface defects, scratches, oxidation, oil contamination
- Hardness check (HRB/HRC) for critical applications
- Coil/lot number recorded in our material registry for full traceability
FAI — First Article Inspection
- CMM measurement of all critical dimensions on the first article (not just key dimensions)
- Comparison against customer drawing — every dimension, every tolerance
- Bend angle verification with angle gauge (±0.5° tolerance)
- Weld inspection: visual for penetration, undercut, spatter, distortion
- Surface finish check against specified Ra value or visual standard
- FAI report generated, signed by QC supervisor, sent to customer if requested
IPQC — In-Process Quality Control
- After laser cutting: check burr height (≤0.1mm), edge quality, hole diameter (go/no-go gauge)
- After bending: verify angle with digital protractor, check flange length, check for tooling marks
- During welding: visual inspection every 20-50 pieces for weld consistency, penetration, distortion
- After surface treatment: coating thickness gauge (60-120μm for powder coat), adhesion cross-hatch test
- IPQC check frequency: every 50 pieces or every 2 hours, whichever comes first
- All checks recorded on IPQC sheet with operator ID, time, measurement values
FQC — Final Quality Control
- 100% visual inspection: scratches, dents, weld spatter, coating defects, color mismatch
- Critical dimension sampling (AQL 1.0 per ISO 2859-1 General Inspection Level II)
- Assembly check: fit-up, screw torque, hinge operation, door alignment
- Function test: moving parts, electrical continuity (for enclosures), load test (for carts/frames)
- Surface treatment final check: coating thickness, color match to approved sample, no orange peel
- Each accepted part receives a green QC stamp/sticker with inspector ID and date
OQC — Outgoing Quality Control
- Quantity verification against packing list and purchase order
- Carton/pallet labeling check: part number, quantity, PO number, batch code
- Random sampling from sealed cartons to confirm packing integrity
- Photo documentation: packed goods, pallet photos, container loading photos
- Shipment documentation package compiled: MTR, inspection report, packing list, certificate of conformity
- QC release form signed by QC manager before container leaves
In-House Inspection Equipment
We do not outsource measurement. Every test listed below is performed in our own facility, by our own inspectors, with results available before shipment.
| Equipment | What It Measures | Range / Accuracy | Used At |
|---|---|---|---|
| CMM (Coordinate Measuring Machine) | 3D dimensional verification of complex geometries, hole positions, bend angles | XYZ ±0.005mm | FAI, FQC (sampling) |
| Spectrometer (PMI) | Material composition analysis — verifies Cr, Ni, C, Mn, Si content | 0.001% resolution | IQC |
| Salt Spray Test Chamber | Corrosion resistance of galvanized, powder-coated, and plated parts | ASTM B117, up to 1000h | IQC, FQC (batch) |
| Digital Height Gauge | Vertical dimensions, step heights, depth of features | 0-600mm, ±0.01mm | FAI, IPQC |
| Coating Thickness Gauge | Powder coat, electroplating, galvanizing thickness on steel and aluminum | 0-2000μm, ±1μm | IPQC, FQC |
| Digital Calipers | General dimensional checks — length, width, diameter, depth | 0-300mm, ±0.02mm | All stages |
| Micrometer | Sheet thickness, precise outer dimensions | 0-25mm, ±0.001mm | IQC, FAI |
| Digital Protractor / Angle Gauge | Bend angle verification after press brake forming | 0-360°, ±0.1° | IPQC, FQC |
| Go / No-Go Gauges | Hole diameter, slot width, thread size — pass/fail check | Custom per drawing | IPQC, FQC |
| Surface Roughness Tester | Ra / Rz value for machined or finished surfaces | Ra 0.05-10μm | FAI, FQC |
| Hardness Tester | Material hardness (HRB / HRC / HV) for heat-treated or hardened parts | 20-70 HRC | IQC, FAI |
| Welding Inspection Kit | Weld gauge for fillet size, undercut depth, gap measurement | 0-25mm, ±0.01mm | IPQC, FQC |
| Cross-Hatch Adhesion Tester | Coating adhesion verification per ASTM D3359 | Grade 0-5 | FQC (batch) |
| Torque Wrench (Calibrated) | Bolt/screw torque verification on assembled products | 0-50 Nm, ±2% | FQC (assembly) |
Full Traceability — From Steel Coil to Shipped Part
Every part we ship can be traced back to the raw material lot, the machine that cut it, the operator who bent it, and the inspector who approved it.
Material Lot
Steel coil/sheet assigned lot number at incoming inspection
Nesting & Cut
Lot number linked to nesting program and laser cutting job
Form & Weld
Operator ID, machine number, and process parameters recorded
Inspection
Inspection record linked to part with pass/fail status and values
Shipment
Batch code on packing list links to full production history
What this means for you: If you ever receive a part that does not meet specification, we can trace it back to the exact material lot, the machine, the operator, and the inspection record. We can tell you why it happened and how we will prevent it next time. This is not a promise — it is a documented system we have used since 2016.
When a Part Fails — What Happens Next
No factory produces perfect parts 100% of the time. What matters is how failures are handled. Here is our nonconformance process.
Detect & Tag
Inspector finds a nonconforming part. Red tag applied. Part moved to quarantine area. Production continues only if root cause is not systemic.
Analyze Root Cause
QC supervisor and process engineer investigate. Was it material? Tooling wear? Program error? Operator? Documented on 8D report.
Rework or Scrap
If reworkable: part goes to rework station, then re-inspected (one cycle only). If not: scrapped and counted. Scrap rate tracked monthly.
Prevent Recurrence
Corrective action implemented: tooling replaced, program updated, or operator retrained. Verified on next production run. 8D report filed.
Our Quality Performance
We track these metrics monthly. These are our actual 2025 full-year averages — not targets, not aspirations.
What Comes With Your Shipment
Every shipment includes a documentation package. You do not need to ask for it — it is standard.
Material Test Report (MTR)
Original supplier MTC plus our spectrometer verification result, confirming material grade and composition.
Dimensional Inspection Report
FAI report with CMM data, critical dimensions, and pass/fail status. Available for every production run.
Salt Spray Test Report
Corrosion resistance test result (ASTM B117) for galvanized or coated parts. Duration per customer spec.
Certificate of Conformity (CoC)
Signed document confirming the shipment meets all drawing specifications and purchase order requirements.
Packing List & Batch Codes
Detailed packing list with quantities, batch codes, and traceability references for every carton and pallet.
Photo Documentation
Photos of packed goods, pallets, and container loading. Sent before vessel departure so you can verify.
Internationally Certified & Audited
Our compliance is verified by recognized third-party bodies. Certificate copies available on request.
ISO 9001:2015
Quality Management System — audited annually by accredited certification body
CE Marking
European Conformity — products manufactured to meet EU directives
RoHS 3 Compliant
Restriction of Hazardous Substances — material compliance for all markets
SGS Factory Audit
Third-party factory audit report — available for review by new clients
Frequently Asked Questions
MOQ varies by product complexity. For standard products, MOQ is typically 100-500 pieces. For custom parts, we can accommodate as few as 10-50 pieces for prototyping. Contact us with your requirements for a specific answer.
Standard production lead time is 15-25 days after order confirmation and deposit payment. For urgent orders, we offer expedited production (7-10 days) depending on current capacity. Prototyping typically takes 5-7 days.
Yes. We provide Material Test Reports (MTR) with every shipment. We can also provide dimensional inspection reports, salt spray test results, and third-party test reports upon request. All documents are included in the shipment paperwork.
We accept STEP, IGES, DXF, DWG, PDF, and SolidWorks files. For simple parts, we can also work from 2D drawings or even annotated photos. Our engineering team will review all drawings and confirm manufacturability before quoting.
Absolutely. Our engineering team provides free Design for Manufacturing (DFM) review on every project. We’ll suggest design optimizations that can reduce cost, improve quality, or speed up production — before you commit to an order.
Standard terms: 30% deposit with order, 70% balance before shipment (T/T bank transfer). For established clients with a track record, we can discuss L/C or other terms. We also accept PayPal for sample/prototype orders.
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