Quality Control Standards for Starlink-Compatible Accessories
Quality Control Standards for Starlink-Compatible Accessories
Document Reference: XLC-QC-001
Applicable To: All Wanew Products
Certification: ISO 9001:2015
Approved By: Wanew Quality Management Team
Applicable To: All Wanew Products
Certification: ISO 9001:2015
Approved By: Wanew Quality Management Team
Table of Contents
- 1. Quality Philosophy
- 2. Applicable Standards
- 3. 4-Stage QC Process
- 4. Product-Specific Testing Protocols
- 5. Testing Equipment
- 6. Defect Classification
- 7. Frequently Asked Questions
1. Quality Philosophy
At Wanew, quality is not a department — it is integrated into every stage of production. Our goal is zero defects delivered to the customer. We achieve this through rigorous incoming inspection, in-process monitoring, final functional testing, and continuous improvement based on field data.
Our quality management system is certified to ISO 9001:2015, audited annually by SGS. We maintain a quality defect rate below 0.5% across all product lines, verified by third-party inspections.
We stand behind every product. If a defect is found, we replace it within 15 business days — no questions asked.
2. Applicable Standards
| Standard | Scope | Status |
|---|---|---|
| ISO 9001:2015 | Quality Management System | Certified |
| FCC Part 15 | Electromagnetic emissions (power adapters) | Compliant |
| CE (EN 55032/55035) | EMC and safety for European market | Compliant |
| RoHS (EU 2015/863) | Restriction of hazardous substances | Compliant |
| REACH (EC 1907/2006) | Chemical safety of materials | Compliant |
| ASTM B117 | Salt spray corrosion testing | 500 hours rated |
| ASTM D4329 | UV exposure testing | 5-year equivalent |
| UL 8750 (pending) | LED and power supply safety | In process |
3. 4-Stage QC Process
Stage 1: Incoming Quality Control (IQC)
| Material | Inspection | Acceptance Criteria |
|---|---|---|
| Steel / Aluminum | Dimensional, material grade verification, surface finish | ANSI/ASQ Z1.4 AQL 1.0 |
| Plastic Resin | Melt flow index, color match, impact resistance | Supplier COA + in-house verification |
| Cables / Wire | Conductor gauge, insulation thickness, continuity | 100% on critical lots |
| Hardware (bolts, nuts) | Thread gauge, hardness test, plating thickness | ANSI/ASME B1.1 Class 2A |
Stage 2: In-Process QC (IPQC)
- First Article Inspection (FAI) at start of every production run
- Patrol inspection every 2 hours: dimensional, visual, assembly fit
- Sampling rate: 20% for critical dimensions, 10% for visual
- Any defect triggers 100% inspection of the preceding batch
- Process capability monitoring (CpK) for critical processes
Stage 3: Final Quality Control (FQC)
- 100% functional testing for all products:
- Mounts: Fit test with standard Starlink base plate and hardware
- Adapters: Load test at rated current for 30 minutes
- Cables: Continuity, insulation resistance (>100 M Ohm)
- Assemblies: Torque test on all fasteners
- Dimensional inspection: Sampling per AQL 2.5
- Visual inspection: 100% for surface defects, scratches, discoloration
Stage 4: Outgoing Quality Control (OQC)
- Statistical sampling per AQL 2.5 (normal), AQL 1.0 (critical items)
- Packaging integrity check: label accuracy, barcode scan, seal inspection
- Quantity verification: 100% count for orders under 10,000 units
- Documentation: Certificate of Conformance, inspection report, test results
- Third-party inspection available upon request (SGS, Bureau Veritas, TUV)
4. Product-Specific Testing Protocols
Mounts (Pipe, Wall, Roof)
| Test | Method | Pass Criteria |
|---|---|---|
| Static load test | Apply 20 kg vertical load, 5 minutes | No permanent deformation |
| Torque retention | Tighten to spec, measure after 24h at 60 deg C | Loss < 10% of initial torque |
| Salt spray resistance | ASTM B117, 500 hours | No red rust on critical surfaces |
| UV aging | ASTM D4329, 1,000 hours | No cracking, color change Delta E < 3 |
| Vibration test | IEC 60068-2-6, 5-150 Hz, 2g | No loosening, no damage |
Power Adapters
| Test | Method | Pass Criteria |
|---|---|---|
| Output voltage accuracy | Measure at rated load | +/- 3% of nominal |
| Overcurrent protection | Apply 150% rated current | Shutdown within 2 seconds |
| Short circuit protection | Short output terminals | Automatic recovery within 5 seconds |
| Temperature rise | Full load, 25 deg C ambient, 4 hours | Case temp < 60 deg C |
| Dielectric strength | 1,500V AC, 1 minute | No breakdown, leakage < 5mA |
Cables
| Test | Method | Pass Criteria |
|---|---|---|
| Continuity | 100% of pins tested | All pins continuous, no shorts |
| Insulation resistance | 500V DC, 1 minute | > 100 M Ohm |
| Connector retention | 10N pull test, 1 minute | No disconnection, no damage |
| Bend test | +/- 90 deg, 10,000 cycles | No conductor breakage |
| Cold bend | -40 deg C, 4 hours, bend 180 deg | No jacket cracking |
5. Testing Equipment
| Equipment | Purpose | Calibration |
|---|---|---|
| Universal Testing Machine | Tensile, compression, flexural testing | Annual (certified) |
| Salt Spray Chamber | Corrosion testing (ASTM B117) | Annual |
| UV Weathering Tester | UV aging (ASTM D4329) | Bi-annual |
| Thermal Cycling Chamber | Temperature cycling (-40 to +85 deg C) | Annual |
| CMM (Coordinate Measuring Machine) | Precision dimensional inspection | Annual |
| Torque Wrench Calibrator | Torque tool verification | Quarterly |
| Hi-Pot Tester | Dielectric strength testing | Annual |
| Megohmmeter | Insulation resistance measurement | Annual |
6. Defect Classification
| Class | Definition | Action | AQL |
|---|---|---|---|
| Critical | Safety hazard (exposed live wire, sharp burrs, fire risk) | 100% sort + corrective action | 0% (zero tolerance) |
| Major | Functional failure (does not fit, no output, corrosion) | 100% sort + process correction | AQL 1.0 |
| Minor | Cosmetic issue (scratch, color variation, packaging damage) | AQL sampling + visual standard update | AQL 2.5 |
Zero-Defect Policy: Critical defects are not tolerated at any sampling level. If a single critical defect is found in a lot, the entire lot is quarantined and 100% inspected. The root cause is investigated and corrected before production resumes.
7. Frequently Asked Questions
Can I request third-party inspection of my order?
A: Yes. We welcome third-party inspections from SGS, Bureau Veritas, TUV Rheinland, or any accredited inspection agency. The cost is borne by the buyer. We provide full access to production lines and finished goods for inspection.
What happens if a defect is found after shipment?
A: Notify us within 30 days of receipt. We will request photos or returned samples for analysis. If confirmed as a manufacturing defect, we issue replacement or credit within 15 business days. Shipping cost for replacements is borne by Wanew.
Do you provide test reports with each shipment?
A: Yes. Each shipment includes a Certificate of Conformance (CoC) signed by our QC manager. Upon request, we also provide the Inspection Report (dimensional, functional, visual) and material certifications.
Quality You Can Rely On
Wanew ISO 9001 Certified Quality
Industry-leading QC standards with defect rates below 0.5%. OEM/ODM partnerships welcome.
Email: hello@wanew.com
