Factory Notes · QC Inspection
QC Inspection Checklist for Mass-Production Metal Display Fixtures (AQL 2.5)
At Formost, our QC team checks mass-production metal display fixtures before shipment using a fixed finished-goods checklist and AQL sampling plan. Every defect is classified as Critical, Major, or Minor with a clear accept/reject rule.
Short Answer
Before any mass-production metal display fixture order ships, Formost checks finished goods against a fixed checklist and an AQL sampling plan. Critical defects are zero tolerance (accept on 0, reject on 1), Major defects are judged by AQL 2.5, and Minor defects are judged by AQL 4.0.
This page shows the inspection checklist and defect classification standard Formost uses for mass-production metal display racks, store shelf fixtures, wire display structures, and custom retail display products. For OEM and ODM display rack manufacturing, “passed inspection” should mean the buyer knows exactly what was checked and what the accept/reject rule means.
How We Classify Defects
| Class | What It Means | Typical Display-Rack Examples | Reference Photo | AQL | Lot Action |
|---|---|---|---|---|---|
| Critical | Safety or functional failure; product unusable or unsafe. | Sharp burr or edge, failed structural weld, load-bearing part wrong. | Zero-tolerance issue; no sample photo shown. | 0 | Zero tolerance – lot rejected. |
| Major | Clearly affects function or appearance; a buyer would reject it. | Wrong surface finish or color, missing accessory, out-of-tolerance assembly, dent on a visible face. |  | 2.5 | Accept/reject per AQL 2.5. |
| Minor | Slight deviation; does not affect use. | Faint scratch on a hidden part, minor print misalignment. |  | 4.0 | Accept/reject per AQL 4.0. |
Critical issues are treated differently from appearance defects. If a sample has a safety or structural failure, the lot is rejected regardless of the Major or Minor count.
For OEM and ODM display rack manufacturing, defect classification matters because cosmetic issues, missing accessories, welding problems, and packaging mistakes do not carry the same risk. A sharp burr, a missing caster, and a faint scratch should not be judged by the same rule.
The Finished-Goods Inspection Checklist
| Category | What We Check |
|---|---|
| Packaging & labeling | Carton marks and inner-box printing correct; hang tags, stickers, and manuals complete; packaging method matches specification; customer artwork correct. |
| Surface & appearance | Surface treatment and color match the approved sample; no visible-face defects. |
| Components & accessories | Component parts such as hooks, ropes, casters, end caps, and fasteners match specification; all parts and accessories complete. |
| Dimensions & assembly | Assembled dimensions are within tolerance; parts fit, lock, and assemble correctly. |
| Function & safety | Function and assembly tests passed; safety performance test passed. For higher-risk welded or load-bearing structures, visual weld condition and tapping sound inspection may also be checked to help identify weak welds, loose joints, or abnormal resonance. |
For display fixtures, QC cannot stop at appearance. A clean surface is not enough if hooks do not fit, casters do not lock, accessories are missing, or assembled dimensions are outside tolerance.
How AQL 2.5 Sampling Works
We do not inspect 100% of every order. We inspect a random sample sized by lot quantity, using ISO 2859-1 / ANSI-ASQ Z1.4 General Inspection Level II as the sampling reference, then count defects by class against the AQL limit.
Example: Lot Quantity 501-1,200 pcs, Sample Size 80
| Defect Class | AQL | Accept <= | Reject >= |
|---|---|---|---|
| Critical | 0 | 0 | 1 |
| Major | 2.5 | 5 | 6 |
| Minor | 4.0 | 7 | 8 |
If the sample exceeds the accept number for any class, the lot is held and reworked or re-inspected. It does not ship as-is.
What Buyers Receive
For each order, Formost can provide a finished-goods inspection record with photos of sampled units. Buyers are also welcome to send their own inspector or arrange a third-party inspection company such as SGS, BV, or TÜV for final random inspection before shipment.
QC standards should also connect with product design and surface treatment decisions. For finish-related risks, read our Factory Notes article on powder coating, chrome, E-coating, and galvanizing for retail display racks. For the full project flow, see our custom metal display rack ODM manufacturing guide.
FAQ
What is the difference between Critical, Major, and Minor defects?
Critical defects are safety or functional failures with zero tolerance. Major defects clearly affect function or appearance and would likely be rejected by a buyer. Minor defects are slight cosmetic deviations that do not affect normal use.
What does AQL 2.5 mean?
AQL 2.5 is the Acceptable Quality Limit used for Major defects. In the example of a sample size of 80, up to 5 Major defects are accepted, while 6 or more Major defects reject the lot.
What happens if a lot fails inspection?
The lot is held, then reworked, sorted, or re-inspected. It does not ship as-is until it passes the agreed inspection standard.
Does Formost inspect both appearance and assembly function?
Yes. For metal display racks and retail fixtures, our checklist covers surface appearance, component completeness, dimensions, assembly fit, packaging, labeling, and basic safety or function checks.
Do you provide an inspection report?
Yes. For each order, we can provide a finished-goods inspection record with photos of sampled units and the checked items.
Can buyers use their own or a third-party inspector?
Yes. Buyers are welcome to arrange their own inspector or a third-party inspection company such as SGS, BV, or TÜV for final random inspection before shipment.
Need a Supplier with a Documented QC Process?
Send your product type, drawings, target market, finish requirement, packaging details, and expected quantity. Formost can review the fixture structure, QC checkpoints, and shipment inspection requirements before production.
Discuss Your ProjectFor heavy-duty display rack QC, inspection should not only check appearance and dimensions. Weld penetration, joint stability, load-bearing parts, visual weld condition, and tapping sound inspection may also be reviewed when the structure carries higher risk.