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When manufacturing resin and ceramic action figures, the quality is not realized at the last inspection point, it is built in at each point. Xiamen Mornsun Industrial Co., Ltd. (MornsunGifts) is a company established in 2007 and supported by over 19 years of production experience, with a strict, scientific quality control system to ensure that the figurines, bobbleheads, holidays decorations and miniature models are up to international standards. This article describes the quality control process as it progresses from incoming inspection to pre-shipment inspection and the importance of each stage of the process for action figure manufacturing.
Incoming Inspection: Validating Raw Materials First
Quality control starts as the production process begins. The raw materials are examined on arrival and comprise resin compounds, ceramic clay, bisque, terracotta, glazes, pigments and packaging materials. The incoming inspection checks for consistency, purity and suitability of the material for the desired product. The firing characteristics and color stability of ceramic lines should be checked in clay and glaze batches, and the compound should be checked for its fine detail and complex shape capture. Therefore as the raw material is faulty, it cannot be rectified downstream and this is the first gate to ensure the entire production batch. With a production of over 1.5 million units per month, any slight material change or variation would affect several thousands of units.
In-Process Inspection: Controlling Quality During Production
The in-process inspection controls critical stages of molding, demolding, trimming, assembly and finishing during production. The evaluation of resin crafted items includes bubbles, incomplete fills, warping and surface imperfections and of ceramics, shrinkage and cracking during firing, and even the uniformity of the glazes. Clay and fire make ceramic, so there are some variables to control; for resin, it's detail fidelity. When manufacturing large runs of figurines, bookends, eyeglasses holders and photo frames, in-process checks will help you make the corrections before the defects mount up.
Semi-Finished and Paint Inspection: Protecting Detail and Color
When judging action figures, it is most important to take into account surface detail and paint application. Semi-finished products undergo tests after molding and assembly to confirm that there is no structural defect, joint strength, dimensional tolerances. When a paint inspection is performed, it gives an assurance of color matching, shading, adhesion of coating and cleanliness of detail. Different standards are set for resin and ceramic, as these two materials take paint differently. Seasonal decorations, such as Santa Claus figures, snow globes, nutcrackers, Halloween skulls and pumpkins, and Easter bunnies all need to be done in the same color. The same applies to plaques, wall art, ceramic flowers, and other home accents that are designed to be displayed for aesthetic purposes, as the quality of the finish will also affect the value.
Final and Pre-Shipment Inspection: The Last Line of Defense
Prior to packing, covering (dimensions, appearance, function (for bobbleheads, eyeglass holders and bookends), and labeling), each unit is inspected against the approved prototype and specification. The pre-shipment inspection is then to be carried out according to the sampling criteria on the packaged lot, on carton strength and according to the international quality standards and client's specification, and quantity. Pre-shipment tests are also conducted in response to customer needs in the Americas, Europe and Australia to ensure products meet the expectations of the customers' destination markets. The last gate makes sure that the items leaving the 5719 m² facility are what the customer bargained for, in other words no surprises at the port.
A Quality Culture Behind the System
Systems depend on people! The company's professional staff ensures the quality, while the company has a professional and scientific quality control team to ensure that the quality of the products is up to all requirements. Quality control is a responsibility of each and every person involved in sample approval through to shipment. It has over 10 professional product designers, graphic designers, 3D designers and sculptors and more than 10 years of customer service experience. More than 250 well-known brands have collaborated with us, contributing to what we have learned about the process.
Conclusion
The quality control (QC) of action figures is not a single point but a series of processes. Materials are validated on receipt, the production is controlled with in-process inspection, detail, and colour are protected with paint and semi-finished inspection, and the finished lot is confirmed with final and pre-shipment inspection. Each of these phases is vital to the success of the following one in resin and ceramic manufacturers. This controlled process guarantees that all figurines, decorations and miniature models are delivered to the customers worldwide of high quality.
