Every organization producing aesthetic components must go beyond standard part approval to agree on a defined level of visual assessment with the customer. In the automotive industry, this is often achieved through approval based on a Quality Book.
What is a Quality Book?
Simply put, a Quality Book is a catalog containing images of various zones of a product, specifying the areas to be evaluated. Contrary to what one might think, numerous components in a car require such assessment, including:
- Car seats
- Dashboard
- Door panels
- Floor carpets
- Bumpers
- Trunk compartment elements
- Pillar covers and headliner
- Lamps
- And more
The creation of a Quality Book begins with the launch of a new project when the organization has a finalized process at a defined location. In English, this phase is referred to as Off Tool Off Process (OTOP).
You can also update the Quality Book as needed, based on changes in ongoing production that may affect the product’s aesthetics. From an aesthetic perspective, the Quality Book can address topics such as:
- Wrinkles on car seats
- Correct color matching of painted, plastic, and fabric elements (e.g., rear shelf material)
- Proper graining of injected parts
- Accurate fit and alignment of interface elements
Steps for Approving a Quality Book
Each approval step should begin with the preparation of proper photographic documentation of the component. Ideally, you should take these photos from the same distance as the final customer’s viewing perspective.
Additionally, it’s worth agreeing with the manufacturer on whether the light intensity level [lx] should reflect that used in the client’s final vehicle inspection area. Beyond standard evaluations of “compliant” or “non-compliant,” it’s also beneficial to define borderline (or “border”) variants, accounting for peripheral conditions.
The approval process should involve representatives from the following roles:
Supplier Quality Engineer (SQE)
This person is responsible for approving the production process. Therefore, you should conduct the initial pre-approval with the client’s SQE. Only after this step can the Quality Book be validated with other departments.
Incoming Quality Control Manager
Or their representative. This department is responsible for issuing claims, including those related to non-compliant aesthetics, during ongoing production. Having knowledge of the agreed aesthetic standards ensures they can accurately evaluate the validity of such claims.
Finished Product Audit Representative
Just as suppliers must perform Finished Product Audits, customers also conduct these audits at defined intervals. These include both road testing and static assessments in well-lit tunnels.
Additional Considerations
In addition to approving the paper version with photographic zones, you can also submit physical parts for approval. For components with a broad palette of upholstery and paint finishes, select the most visually prominent colors.
If you choose to approve physical components, you must agree on storage conditions with the client representative. Pay special attention to environmental factors such as direct sunlight and humidity levels in the storage location for physical samples.
By following these steps, a Quality Book becomes an essential tool for ensuring mutual understanding and maintaining high visual quality standards throughout the production process.
Dariusz Kowalczyk
