| Product identity | Shape, color, quantity per set, block dimensions, magnet position, and packaging must match the approved purchase specification and sample. | Compare production goods with the signed specification, approved sample, artwork, and packing list. | Major | AQL 1.5 |
| Foam material | Closed-cell foam should be clean, evenly colored, free from oil stains, mold, sharp edges, embedded debris, and excessive odor. | Visual inspection under good lighting; check odor and surface condition after opening random cartons. | Major / Minor | AQL 1.5 for functional or safety-related defects; AQL 4.0 for minor cosmetic variation |
| Dimensions and tolerance | Recommended tolerance: ±1.0 mm for blocks up to 50 mm; ±2.0 mm for larger blocks, unless the purchase specification states otherwise. | Measure length, width, and thickness with a calibrated digital caliper. Take at least two readings per dimension. | Major | AQL 1.5 |
| Magnet presence and polarity | Every block requiring a magnet must contain the correct number, location, orientation, and polarity of magnets. | Use a reference magnet or polarity tester; inspect accessible magnet positions and verify assembly orientation. | Major | AQL 1.5 |
| Magnet retention | Magnets must not detach, protrude, or become loose during normal handling, assembly, and reasonable drop simulation. | Perform visual inspection, manual pull check, and a documented drop or impact test agreed in the specification. | Critical / Major | Critical defect: Ac 0 / Re 1; other failures: AQL 1.5 |
| Edges and corners | Edges should be smooth and corners should not have sharp points, exposed wire, cutting flash, or large tears. | Visual and fingertip inspection using clean gloves; inspect all accessible sides of sampled pieces. | Major | AQL 1.5 |
| Color and printing | Color must be reasonably consistent within the same set; printing must be legible, dry, centered, and resistant to light rubbing. | Compare with the approved color standard; perform a dry-rub test and inspect print registration. | Minor / Major | AQL 4.0 for acceptable minor variation; AQL 1.5 for unreadable or incorrect printing |
| Set completeness | Each retail or wholesale set must contain the specified number and assortment of blocks, inserts, instructions, and accessories. | Open sampled sets and count every component against the approved packing specification. | Major | AQL 1.5 |
| Packaging and carton condition | Inner packaging must protect the foam and magnets; cartons should be dry, sealed, correctly marked, and free from crushing that affects product quality. | Inspect carton integrity, labels, carton quantity, gross weight, and moisture or compression damage. | Minor / Major | AQL 4.0 for cosmetic packaging issues; AQL 1.5 for damage affecting saleability or protection |
| Odor and cleanliness | No strong chemical odor, visible contamination, insects, mold, or foreign material should be present in the product or packaging. | Open cartons from different pallet locations and inspect products, bags, and inserts. | Major / Critical | Critical contamination: Ac 0 / Re 1; other defects: AQL 1.5 |
| Documentation and traceability | Inspection records should identify production date, lot number, quantity, material information, test results, and corrective-action status. | Review supplier records, lot identification, test reports, and pre-shipment inspection photographs. | Major | AQL 1.5 when missing records prevent product release |