Defect Analysis by Production Line

Department-specific defects and their impact on output — Jan–Jun 2026

Chassis

Welded metal seat-frame fabrication — robotic MIG welding of frame members, grinding of welds, straightness inspection, and surface protection of the bare frame skeleton.

Inspected: 357,348Defects: 1,982Avg PPM: 5,546 / 4,800

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Welding	132	114	160	132	106	200	118	114	181	284	1541	77.7%	Porosity, spatter, or incomplete fusion at frame welds — weakens the structural integrity of the seat frame and risks frame failure under load or crash.
Grinding	15	36	28	53	20	40	25	32	15	53	317	16.0%	Weld material not ground flush — leaves sharp edges and uneven surface that can cut the foam/trim or cause fit-up problems downstream.
Assembly	—	—	—	5	10	14	10	5	20	—	64	3.2%	Hardware or clips mis-installed on the frame — missing or loose mounting points affect downstream assembly and vehicle fit.
Straightness	8	5	7	—	—	—	—	5	9	10	44	2.2%	Frame geometry out of tolerance — causes assembly misalignment and gaps when mounting foam and trim.
Parts Shift	15	6	2	2	6	—	—	—	—	—	31	1.6%	Frame components shifted during welding — dimensional drift from the CAD model propagates to every downstream station.
Line Total	155	161	197	192	142	254	153	156	225	347	1982	100%	Aggregate defects for Chassis across Jan–Jun 2026.

Foam (Line 1)

Polyurethane foam molding line (Line 1) — pours and cures the seat cushion foam core; includes cutting, trimming, and vacuum molding of the finished foam block.

Inspected: 369,794Defects: 3,598Avg PPM: 9,730 / 11,800

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Vacuities	110	77	118	75	120	140	180	200	173	181	1374	38.2%	Internal voids/air pockets in the cured foam — reduced cushioning density and visible depressions in the finished seat.
Cutting	176	120	95	100	50	135	115	190	203	150	1334	37.1%	Foam cut off-spec (dimensions or density) — cushion does not fit the frame or trim cover, leaving gaps or compression issues.
Trimming	30	45	75	45	—	25	15	45	32	125	437	12.1%	Flash or excess foam not trimmed — interferes with trim cover fit and creates visible bulges.
Shift	43	35	10	55	35	10	10	95	15	—	308	8.6%	Foam core shifted inside the mold — asymmetric cushion and uneven bolster support.
Grinding	20	30	20	20	15	25	10	—	—	—	140	3.9%	Rough foam skin after molding — surface tears or uneven contour that affects comfort and cover fit.
Cleanliness	5	—	—	—	—	—	—	—	—	—	5	0.1%	Foreign matter (dust, release agent) on the foam skin — bonding failure with the trim cover and contamination of the finished seat.
Line Total	384	307	318	295	220	335	330	530	423	456	3598	100%	Aggregate defects for Foam (Line 1) across Jan–Jun 2026.

Trim (Line 1)

Seat trim cover sewing line (Line 1) — cuts fabric/leather panels, sews them into the cover, and assembles the finished trim cover for the seat.

Inspected: 311,367Defects: 5,695Avg PPM: 18,290 / 5,500

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Sewing Cut	152	190	70	428	197	301	141	120	94	101	1794	31.5%	Fabric cut or severed at the sewing line — seam integrity is lost and the cover tears under tension.
Assembly Defects	112	122	95	447	194	235	121	110	71	83	1590	27.9%	Cover assembled incorrectly (orientation or attachments) — fit and function failure of the cover.
Wrinkles	55	111	62	302	130	110	125	75	67	66	1103	19.4%	Puckered or wrinkled material after sewing — poor appearance and uneven fit over the foam.
Tafzeer	28	44	27	171	65	84	63	92	24	18	616	10.8%	Excess fabric bunching/overlap at the seam — dimensional distortion and a visible lump in the cover.
Stitch Defects	16	35	38	52	48	14	15	16	13	15	262	4.6%	Skipped or uneven stitches — seam strength below spec; the cover may split in use.
Material	23	19	40	—	29	—	—	—	—	—	111	1.9%	Incoming fabric/leather defect (weave, dye, grain) — cosmetic non-conformity on a customer-visible surface.
Extra Thread	5	79	26	—	—	—	—	—	—	—	110	1.9%	Loose thread tails not trimmed — cosmetic defect and snag risk on the finished seat.
Stitch Effects	—	16	6	—	—	—	—	—	19	47	88	1.5%	Stitch pattern distortion — cosmetic defect on the visible seam.
Dimensions	10	—	6	5	—	—	—	—	—	—	21	0.4%	Trim cover dimensions out of tolerance — loose or tight fit on the foam and frame.
Line Total	401	616	370	1405	663	744	465	413	288	330	5695	100%	Aggregate defects for Trim (Line 1) across Jan–Jun 2026.

GM Assembly

Final seat assembly line for GM vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 80,596Defects: 559Avg PPM: 6,936 / 3,600

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Assembly	33	62	7	98	20	47	35	6	46	27	381	68.2%	Incorrect mounting of foam, trim, or hardware onto the frame — functional non-conformity; the seat may not attach to the vehicle or operate correctly.
Scratches	5	—	10	1	—	16	28	—	5	2	67	12.0%	Surface scratches on the finished trim or frame — cosmetic defect on a customer-visible part.
Sewing	—	5	8	7	7	20	—	4	—	6	57	10.2%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Wrinkles	6	—	5	8	—	—	—	4	5	26	54	9.7%	Wrinkles from mispulling the cover during assembly — appearance defect on the finished seat.
Line Total	44	67	30	114	27	83	63	14	56	61	559	100%	Aggregate defects for GM Assembly across Jan–Jun 2026.

Kasrawy Assembly

Final seat assembly line for Kasrawy vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 24,651Defects: 146Avg PPM: 5,923 / 8,700

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Assembly	—	—	9	4	—	53	2	4	20	28	120	82.2%	Incorrect mounting of foam, trim, or hardware onto the frame — functional non-conformity; the seat may not attach to the vehicle or operate correctly.
Sewing	—	—	2	1	—	—	9	1	—	—	13	8.9%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Scratches	—	—	2	—	—	3	2	—	1	—	8	5.5%	Surface scratches on the finished trim or frame — cosmetic defect on a customer-visible part.
Wrinkles	—	—	—	—	—	—	—	—	3	—	3	2.1%	Wrinkles from mispulling the cover during assembly — appearance defect on the finished seat.
Rust & Dirty	—	—	—	—	—	—	—	2	—	—	2	1.4%	Corrosion or soiling on the finished seat — contamination and cosmetic defect at final QC.
Line Total	0	0	13	5	0	56	13	7	24	28	146	100%	Aggregate defects for Kasrawy Assembly across Jan–Jun 2026.

Proton Assembly

Final seat assembly line for Proton vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 16,040Defects: 6Avg PPM: 374 / 2,000

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Sewing	—	5	—	—	—	—	—	—	—	—	5	83.3%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Assembly	—	—	—	—	—	1	—	—	—	—	1	16.7%	Incorrect mounting of foam, trim, or hardware onto the frame — functional non-conformity; the seat may not attach to the vehicle or operate correctly.
Line Total	0	5	0	0	0	1	0	0	0	0	6	100%	Aggregate defects for Proton Assembly across Jan–Jun 2026.

GEELY Assembly

Final seat assembly line for GEELY vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 32,040Defects: 112Avg PPM: 3,496 / 4,750

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Assembly	7	—	6	1	—	12	5	9	2	2	44	39.3%	Incorrect mounting of foam, trim, or hardware onto the frame — functional non-conformity; the seat may not attach to the vehicle or operate correctly.
Scratches	—	4	4	7	3	4	—	—	11	2	35	31.3%	Surface scratches on the finished trim or frame — cosmetic defect on a customer-visible part.
Sewing	—	—	—	1	7	—	—	—	1	10	19	17.0%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Wrinkles	—	—	—	—	—	2	—	—	4	5	11	9.8%	Wrinkles from mispulling the cover during assembly — appearance defect on the finished seat.
Rust & Dirty	—	—	—	—	—	—	—	—	—	3	3	2.7%	Corrosion or soiling on the finished seat — contamination and cosmetic defect at final QC.
Line Total	7	4	10	9	10	18	5	9	18	22	112	100%	Aggregate defects for GEELY Assembly across Jan–Jun 2026.

Nissan Assembly

Final seat assembly line for Nissan vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 130,124Defects: 383Avg PPM: 2,943 / 900

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Assembly	36	3	3	20	2	1	6	26	33	14	144	37.6%	Incorrect mounting of foam, trim, or hardware onto the frame — functional non-conformity; the seat may not attach to the vehicle or operate correctly.
Sewing	6	7	23	5	3	—	8	10	6	24	92	24.0%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Scratches	24	2	6	17	3	7	7	13	5	7	91	23.8%	Surface scratches on the finished trim or frame — cosmetic defect on a customer-visible part.
Rust & Dirty	10	2	12	13	—	—	3	—	—	—	40	10.4%	Corrosion or soiling on the finished seat — contamination and cosmetic defect at final QC.
Wrinkles	2	—	—	—	—	—	—	8	6	—	16	4.2%	Wrinkles from mispulling the cover during assembly — appearance defect on the finished seat.
Line Total	78	14	44	55	8	8	24	57	50	45	383	100%	Aggregate defects for Nissan Assembly across Jan–Jun 2026.

Foam (Line 2)

Polyurethane foam molding line (Line 2) — pours and cures the seat cushion foam core; includes cutting, trimming, and vacuum molding of the finished foam block.

Inspected: 88,798Defects: 1,024Avg PPM: 11,532 / 8,600

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Vacuities	21	18	27	20	27	50	13	21	74	353	624	60.9%	Internal voids/air pockets in the cured foam — reduced cushioning density and visible depressions in the finished seat.
Cleanliness	14	—	8	10	6	15	10	6	95	22	186	18.2%	Foreign matter (dust, release agent) on the foam skin — bonding failure with the trim cover and contamination of the finished seat.
Shift	19	25	15	7	7	22	22	—	—	8	125	12.2%	Foam core shifted inside the mold — asymmetric cushion and uneven bolster support.
Grinding	12	7	8	—	—	—	8	—	—	—	35	3.4%	Rough foam skin after molding — surface tears or uneven contour that affects comfort and cover fit.
Trimming	—	9	—	6	—	—	6	9	—	—	30	2.9%	Flash or excess foam not trimmed — interferes with trim cover fit and creates visible bulges.
Cutting	—	—	—	—	—	—	—	17	—	7	24	2.3%	Foam cut off-spec (dimensions or density) — cushion does not fit the frame or trim cover, leaving gaps or compression issues.
Line Total	66	59	58	43	40	87	59	53	169	390	1024	100%	Aggregate defects for Foam (Line 2) across Jan–Jun 2026.

Trim Cover (Line 2)

Seat trim cover sewing line (Line 2) — cuts fabric/leather panels, sews them into the cover, and assembles the finished trim cover for the seat.

Inspected: 107,816Defects: 723Avg PPM: 6,706 / 6,400

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Assembly	5	26	38	13	14	30	15	19	9	14	183	25.3%	Cover assembled incorrectly (orientation or attachments) — fit and function failure of the cover.
Unstitched	19	18	40	30	8	28	3	—	3	—	149	20.6%	Open seam where stitching is missing — the seam separates under load.
Tafzeer	18	—	10	9	13	11	—	7	2	18	88	12.2%	Excess fabric bunching/overlap at the seam — dimensional distortion and a visible lump in the cover.
Baso	17	7	—	10	—	15	—	11	8	9	77	10.7%	Excess material at a seam junction — localized thickness that affects comfort and fit.
Stitch Effects	6	4	7	—	5	4	—	35	3	3	67	9.3%	Stitch pattern distortion — cosmetic defect on the visible seam.
Finishing	—	10	3	—	—	5	8	—	9	30	65	9.0%	Final finishing defect (thread, edge) — cosmetic non-conformity on the finished cover.
Material	9	17	5	—	—	8	—	—	8	16	63	8.7%	Incoming fabric/leather defect (weave, dye, grain) — cosmetic non-conformity on a customer-visible surface.
Impregnation	5	8	—	5	—	—	5	5	3	—	31	4.3%	Lamination/backing impregnation defect — material layers delaminate and the cover loses durability.
Line Total	79	90	103	67	40	101	31	77	45	90	723	100%	Aggregate defects for Trim Cover (Line 2) across Jan–Jun 2026.

BMW

Final seat assembly line for BMW vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 4,176Defects: 3Avg PPM: 718 / 2,500

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Scratches	—	2	—	—	—	—	—	—	—	—	2	66.7%	Surface scratches on the finished trim or frame — cosmetic defect on a customer-visible part.
Sewing	—	1	—	—	—	—	—	—	—	—	1	33.3%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Line Total	0	3	0	0	0	0	0	0	0	0	3	100%	Aggregate defects for BMW across Jan–Jun 2026.

Toyota

Final seat assembly line for Toyota vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 8,392Defects: 11Avg PPM: 1,311 / 2,150

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Assembly	—	2	—	1	—	—	—	—	3	1	7	63.6%	Incorrect mounting of foam, trim, or hardware onto the frame — functional non-conformity; the seat may not attach to the vehicle or operate correctly.
Sewing	—	—	—	1	1	1	—	—	—	—	3	27.3%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Scratches	—	—	—	—	—	—	—	1	—	—	1	9.1%	Surface scratches on the finished trim or frame — cosmetic defect on a customer-visible part.
Line Total	0	2	0	2	1	1	0	1	3	1	11	100%	Aggregate defects for Toyota across Jan–Jun 2026.

Citroen

Final seat assembly line for Citroen vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 1,440Defects: 1Avg PPM: 694 / 4,000

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Sewing	—	—	—	1	—	—	—	—	—	—	1	100.0%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Line Total	0	0	0	1	0	0	0	0	0	0	1	100%	Aggregate defects for Citroen across Jan–Jun 2026.

Abo Elftoh (Tiggo7)

Final seat assembly line for Abo Elftoh (Tiggo7) vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 8,405Defects: 23Avg PPM: 2,736 / 3,000

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Assembly	2	3	1	3	3	—	—	—	—	—	12	52.2%	Incorrect mounting of foam, trim, or hardware onto the frame — functional non-conformity; the seat may not attach to the vehicle or operate correctly.
Sewing	3	3	1	2	—	—	—	—	—	—	9	39.1%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Scratches	—	1	1	—	—	—	—	—	—	—	2	8.7%	Surface scratches on the finished trim or frame — cosmetic defect on a customer-visible part.
Line Total	5	7	3	5	3	0	0	0	0	0	23	100%	Aggregate defects for Abo Elftoh (Tiggo7) across Jan–Jun 2026.

Geyushi (Mini Bus - Stecable)

Final seat assembly line for Geyushi (Mini Bus) vehicles — mounts foam and trim cover onto the frame, attaches hardware, and runs outgoing QC.

Inspected: 7,147Defects: 200Avg PPM: 27,984 / 9,000

Defect Type	Jan	Feb	Mar	Apr	May	Jun	Total	% Share	Impact on Output
Assembly	—	—	—	—	—	18	14	4	103	60	199	99.5%	Incorrect mounting of foam, trim, or hardware onto the frame — functional non-conformity; the seat may not attach to the vehicle or operate correctly.
Sewing	—	—	—	—	—	1	—	—	—	—	1	0.5%	Sewing defect introduced at final assembly — seam non-conformity on the attached cover.
Line Total	0	0	0	0	0	19	14	4	103	60	200	100%	Aggregate defects for Geyushi (Mini Bus - Stecable) across Jan–Jun 2026.