Edit with
Total inspected, defects, and average PPM per line (Jan–Aug 2026).
| Line | Department | Inspected | Defects | Avg PPM | Target | Status |
|---|---|---|---|---|---|---|
| Chassis | Chassis / Frame Fabrication | 357,348 | 1982 | 5,546 | 4,800 | ⚠ ABOVE |
| Foam (Line 1) | Foam Molding | 369,794 | 3598 | 9,730 | 11,800 | ✓ OK |
| Trim (Line 1) | Trim Cover Sewing | 311,367 | 5695 | 18,290 | 5,500 | ⚠ ABOVE |
| GM Assembly | Final Seat Assembly | 80,596 | 559 | 6,936 | 3,600 | ⚠ ABOVE |
| Kasrawy Assembly | Final Seat Assembly | 24,651 | 146 | 5,923 | 8,700 | ✓ OK |
| Proton Assembly | Final Seat Assembly | 16,040 | 6 | 374 | 2,000 | ✓ OK |
| GEELY Assembly | Final Seat Assembly | 32,040 | 112 | 3,496 | 4,750 | ✓ OK |
| Exceed Assembly | Final Seat Assembly | 1,969 | 0 | 0 | 2,000 | ✓ OK |
| Mercedes Assembly | Final Seat Assembly | 4,101 | 0 | 0 | 600 | ✓ OK |
| Nissan Assembly | Final Seat Assembly | 130,124 | 383 | 2,943 | 900 | ⚠ ABOVE |
| Suzuki Assembly | Final Seat Assembly | 0 | 0 | 0 | 4,000 | ✓ OK |
| Foam (Line 2) | Foam Molding | 88,798 | 1024 | 11,532 | 8,600 | ⚠ ABOVE |
| Trim Cover (Line 2) | Trim Cover Sewing | 107,816 | 723 | 6,706 | 6,400 | ⚠ ABOVE |
| BMW | Final Seat Assembly | 4,176 | 3 | 718 | 2,500 | ✓ OK |
| Toyota | Final Seat Assembly | 8,392 | 11 | 1,311 | 2,150 | ✓ OK |
| Cherokee | Final Seat Assembly | 665 | 0 | 0 | 1,300 | ✓ OK |
| Citroen | Final Seat Assembly | 1,440 | 1 | 694 | 4,000 | ✓ OK |
| Ghabbour (Accent-Tiggo7) | Final Seat Assembly | 40 | 0 | 0 | 3,600 | ✓ OK |
| Abo Elftoh (Tiggo7) | Final Seat Assembly | 8,405 | 23 | 2,736 | 3,000 | ✓ OK |
| Geyushi (Mini Bus - Stecable) | Final Seat Assembly | 7,147 | 200 | 27,984 | 9,000 | ⚠ ABOVE |
| Dongfeng | Final Seat Assembly | 0 | 0 | 0 | — | — |
| Total | 1,554,909 | 14,466 | 9,303 | |||
Each station in the production line, the defects that originate there, and why they are attributed to that stage.
Fabric/leather panel cutting and foam block cutting to dimensional spec.
Robotic MIG welding of chassis frame members and geometry control.
Polyurethane pour, cure, and demold of the cushion foam core.
Flash and excess foam/skin trimming after molding.
Weld grinding, surface protection, painting, and rust prevention.
Trim cover panel sewing, stitching, and seam formation.
Incoming fabric/leather and laminate/backing inspection.
Mounting foam, trim cover, and hardware onto the frame.
Final inspection, surface finishing, scratches/soiling control, outgoing QC.
Defects grouped by the production station where they originate — Jan–Aug 2026. Click a bar or slice to drill down by product model
Station Color Key
Each cell = total defects of that type for the product model (Jan–Sep 2026). Hotter cells = more defects.
| Product Model | Assembly | Assembly Defects | Baso | Cleanliness | Cutting | Dimensions | Extra Thread | Finishing | Grinding | Impregnation | Material | Parts Shift | Sewing | Sewing Cut | Shift | Stitch Defects | Stitch Effects | Straightness | Tafzeer | Trimming | Unstitched | Vacuities | Welding | Wrinkles | Total |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| RT50 | 52 | 416 | · | · | 110 | 5 | · | 5 | 131 | 8 | 14 | 6 | · | 419 | 30 | 20 | 6 | 5 | 223 | 125 | 23 | 180 | 247 | 295 | 2320 |
| L02B | · | 203 | · | 5 | 245 | · | 43 | · | 95 | · | 34 | · | · | 357 | 25 | 75 | · | · | 131 | 90 | · | 340 | · | 297 | 1940 |
| 310 C | · | 179 | · | · | 161 | 10 | 43 | · | · | · | · | 16 | · | 244 | 83 | 36 | · | · | 23 | 10 | · | 40 | 74 | 115 | 1034 |
| Geely | · | 233 | · | · | 110 | · | 9 | · | · | · | 15 | · | · | 101 | · | 35 | · | 5 | 40 | · | · | · | 10 | 51 | 609 |
| Kasrawy (القصراوى) | 4 | 80 | · | · | · | · | · | · | 76 | · | 34 | 5 | · | 154 | · | · | · | · | 23 | · | · | · | 197 | 31 | 604 |
| VL | 15 | 113 | · | · | 15 | 6 | 5 | · | 10 | · | 3 | · | · | 130 | 60 | 26 | · | · | 32 | · | · | 55 | 44 | 58 | 572 |
| NISSAN | · | · | · | · | · | · | · | · | 19 | · | · | · | · | · | · | · | · | 7 | · | · | · | · | 245 | · | 271 |
| Geyushi | 27 | · | 15 | · | · | · | · | · | 8 | · | · | · | · | · | 31 | · | 5 | · | 24 | · | 31 | 74 | · | · | 215 |
| PY1B | · | · | · | · | 30 | · | · | · | 10 | · | · | · | · | · | · | · | · | · | · | · | · | 60 | 96 | · | 196 |
| Proton | 15 | · | 5 | · | 75 | · | · | · | · | 7 | 3 | · | · | · | · | · | · | · | 5 | 10 | 51 | 25 | · | · | 196 |
| Tiggo 7 | 7 | · | 5 | 20 | · | · | · | · | · | · | 5 | · | · | · | 53 | · | 4 | · | · | 21 | 9 | 55 | · | · | 179 |
| TOYOTA | 26 | · | 12 | 19 | · | · | · | 3 | · | 8 | 5 | · | · | · | 27 | · | 4 | · | 18 | · | 11 | 29 | · | · | 162 |
| Office Chair (Stecable) | 139 | · | · | · | · | · | · | · | · | · | · | · | 1 | · | · | · | · | · | · | · | · | · | · | · | 140 |
| Kasrawy (قصراوى) | · | · | · | · | 35 | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | 95 | · | · | 130 |
| Jetour | · | 41 | · | · | · | · | · | · | · | · | 7 | · | · | 35 | · | 16 | · | · | · | · | · | · | · | 31 | 130 |
| OFFICE | 8 | · | 7 | 24 | · | · | · | 15 | 27 | · | 5 | · | · | · | 6 | · | · | · | · | · | · | 18 | · | · | 110 |
| Kasrawy | 21 | · | 5 | · | · | · | · | 3 | · | · | 9 | · | · | · | · | · | 7 | · | 14 | · | 21 | · | · | · | 80 |
| JAC | · | 39 | · | · | · | · | · | · | · | · | 5 | · | · | 8 | · | 5 | · | · | 3 | · | · | · | · | 6 | 66 |
| VAN | · | · | · | · | · | · | 10 | · | 5 | · | · | 4 | · | · | · | · | · | · | · | · | · | · | 32 | · | 51 |
| L12F | · | 9 | · | · | · | · | · | · | · | · | 7 | · | · | 12 | · | · | · | · | 4 | · | · | · | · | 6 | 38 |
| 310 S | · | 8 | · | · | · | · | · | · | · | · | 2 | · | · | 14 | · | 2 | · | · | · | · | · | · | 7 | · | 33 |
| Gyushei | · | 5 | · | · | · | · | · | · | · | · | 2 | · | · | 5 | · | 3 | · | · | 3 | · | · | · | · | 5 | 23 |
| GEELY | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | 20 | · | · | 20 |
| Gyushi | · | · | · | · | · | · | · | · | 5 | · | · | · | · | · | · | · | · | · | · | · | · | · | 10 | · | 15 |
| Exceed | · | · | · | · | 10 | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | · | 5 | · | · | 15 |
| 310 | 5 | · | · | · | · | · | · | · | 6 | · | · | · | · | · | · | · | · | 3 | · | · | · | · | · | · | 14 |
For Foam Line 1 & 2 and Trim Line 1 & 2, every defect is grouped under the station where it originates, with monthly counts and the root cause at that stage.
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.
Fabric/leather panel cutting and foam block cutting to dimensional spec.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Cutting▾ models | 176 | 120 | 95 | 100 | 50 | 135 | 115 | 190 | 203 | 150 | 1334 | Foam cut off-spec (dimensions or density) — cushion does not fit the frame or trim cover, leaving gaps or compression issues. |
Polyurethane pour, cure, and demold of the cushion foam core.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Vacuities▾ models | 110 | 77 | 118 | 75 | 120 | 140 | 180 | 200 | 173 | 181 | 1374 | Internal voids/air pockets in the cured foam — reduced cushioning density and visible depressions in the finished seat. | |
| Shift▾ models | 43 | 35 | 10 | 55 | 35 | 10 | 10 | 95 | 15 | · | 308 | Foam core shifted inside the mold during cure — asymmetric cushion and uneven bolster support. | |
| Cleanliness▾ models | 5 | · | · | · | · | · | · | · | · | · | 5 | Foreign matter (dust, release agent) on the foam skin — bonding failure with the trim cover and contamination of the finished seat. |
Flash and excess foam/skin trimming after molding.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Grinding▾ models | 20 | 30 | 20 | 20 | 15 | 25 | 10 | · | · | · | 140 | Rough foam skin after molding — surface tears or uneven contour that affects comfort and cover fit. | |
| Trimming▾ models | 30 | 45 | 75 | 45 | · | 25 | 15 | 45 | 32 | 125 | 437 | Flash or excess foam not trimmed — interferes with trim cover fit and creates visible bulges. |
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.
Fabric/leather panel cutting and foam block cutting to dimensional spec.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Cutting▾ models | · | · | · | · | · | · | · | 17 | · | 7 | 24 | Foam cut off-spec (dimensions or density) — cushion does not fit the frame or trim cover, leaving gaps or compression issues. |
Polyurethane pour, cure, and demold of the cushion foam core.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Vacuities▾ models | 21 | 18 | 27 | 20 | 27 | 50 | 13 | 21 | 74 | 353 | 624 | Internal voids/air pockets in the cured foam — reduced cushioning density and visible depressions in the finished seat. | |
| Shift▾ models | 19 | 25 | 15 | 7 | 7 | 22 | 22 | · | · | 8 | 125 | Foam core shifted inside the mold during cure — asymmetric cushion and uneven bolster support. | |
| Cleanliness▾ models | 14 | · | 8 | 10 | 6 | 15 | 10 | 6 | 95 | 22 | 186 | Foreign matter (dust, release agent) on the foam skin — bonding failure with the trim cover and contamination of the finished seat. |
Flash and excess foam/skin trimming after molding.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Grinding▾ models | 12 | 7 | 8 | · | · | · | 8 | · | · | · | 35 | Rough foam skin after molding — surface tears or uneven contour that affects comfort and cover fit. | |
| Trimming▾ models | · | 9 | · | 6 | · | · | 6 | 9 | · | · | 30 | Flash or excess foam not trimmed — interferes with trim cover fit and creates visible bulges. |
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.
Fabric/leather panel cutting and foam block cutting to dimensional spec.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Dimensions▾ models | 10 | · | 6 | 5 | · | · | · | · | · | · | 21 | Trim cover dimensions out of tolerance from cutting — loose or tight fit on the foam and frame. |
Trim cover panel sewing, stitching, and seam formation.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Extra Thread▾ models | 5 | 79 | 26 | · | · | · | · | · | · | · | 110 | Loose thread tails not trimmed — cosmetic defect and snag risk on the finished seat. | |
| Sewing Cut▾ models | 152 | 190 | 70 | 428 | 197 | 301 | 141 | 120 | 94 | 101 | 1794 | Fabric cut or severed at the sewing line — seam integrity is lost and the cover tears under tension. | |
| Stitch Defects▾ models | 16 | 35 | 38 | 52 | 48 | 14 | 15 | 16 | 13 | 15 | 262 | Skipped or uneven stitches — seam strength below spec; the cover may split in use. | |
| Tafzeer▾ models | 28 | 44 | 27 | 171 | 65 | 84 | 63 | 92 | 24 | 18 | 616 | Excess fabric bunching/overlap at the seam — dimensional distortion and a visible lump in the cover. | |
| Wrinkles▾ models | 55 | 111 | 62 | 302 | 130 | 110 | 125 | 75 | 67 | 66 | 1103 | Puckered or wrinkled material after sewing — poor appearance and uneven fit over the foam. | |
| Stitch Effects▾ models | · | 16 | 6 | · | · | · | · | · | 19 | 47 | 88 | Stitch pattern distortion — cosmetic defect on the visible seam. |
Incoming fabric/leather and laminate/backing inspection.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Material▾ models | 23 | 19 | 40 | · | 29 | · | · | · | · | · | 111 | Incoming fabric/leather defect (weave, dye, grain) — cosmetic non-conformity on a customer-visible surface. |
Mounting foam, trim cover, and hardware onto the frame.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Assembly Defects▾ models | 112 | 122 | 95 | 447 | 194 | 235 | 121 | 110 | 71 | 83 | 1590 | Cover assembled incorrectly (orientation or attachments) — fit and function failure of the cover. |
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.
Trim cover panel sewing, stitching, and seam formation.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Unstitched▾ models | 19 | 18 | 40 | 30 | 8 | 28 | 3 | · | 3 | · | 149 | Open seam where stitching is missing — the seam separates under load. | |
| Tafzeer▾ models | 18 | · | 10 | 9 | 13 | 11 | · | 7 | 2 | 18 | 88 | Excess fabric bunching/overlap at the seam — dimensional distortion and a visible lump in the cover. | |
| Baso▾ models | 17 | 7 | · | 10 | · | 15 | · | 11 | 8 | 9 | 77 | Excess material at a seam junction — localized thickness that affects comfort and fit. | |
| Stitch Effects▾ models | 6 | 4 | 7 | · | 5 | 4 | · | 35 | 3 | 3 | 67 | Stitch pattern distortion — cosmetic defect on the visible seam. |
Incoming fabric/leather and laminate/backing inspection.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Material▾ models | 9 | 17 | 5 | · | · | 8 | · | · | 8 | 16 | 63 | Incoming fabric/leather defect (weave, dye, grain) — cosmetic non-conformity on a customer-visible surface. | |
| Impregnation▾ models | 5 | 8 | · | 5 | · | · | 5 | 5 | 3 | · | 31 | Lamination/backing impregnation defect — material layers delaminate and the cover loses durability. |
Mounting foam, trim cover, and hardware onto the frame.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Assembly▾ models | 5 | 26 | 38 | 13 | 14 | 30 | 15 | 19 | 9 | 14 | 183 | Cover assembled incorrectly (orientation or attachments) — fit and function failure of the cover. |
Final inspection, surface finishing, scratches/soiling control, outgoing QC.
| Defect | Jan | Feb | Mar | Apr | May | Jun | Jul | Aug | Sep | Oct | Total | Root Cause at this Station | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Finishing▾ models | · | 10 | 3 | · | · | 5 | 8 | · | 9 | 30 | 65 | Final finishing defect (thread, edge) — cosmetic non-conformity on the finished cover. |