Shell and material
Start with the shell, because it is the hardest thing to fix after production. Check impact resistance by feel and by the factory’s material grade: PC, ABS+PC and alloy composite behave differently, and the grade should match what was quoted — not just the word “PC” on a page. Look for color consistency across the set, uniform groove depth on line-frame shells, and no visible sink marks, warping or thin spots near corners.
Check the shell under good light, from multiple angles, and compare several units from the same batch. Color drift between units is the most common cosmetic failure in multi-color programs, and it is cheapest to catch before packing.
Frame, zipper and closure
On aluminum-frame cases, close and latch the case repeatedly: the frame must meet evenly all round, latches must engage with a firm click, and the seal must sit flat with no gaps. Misaligned frames are a mold or assembly problem, not a cosmetic one — they worsen with use. On zip cases, run the zipper the full length several times under a loaded case: it must run smoothly with no catching, and the zipper must not burst when the case is full and lifted by the handle.
On line-frame and arc-frame shells, check that grooves and curves are symmetrical left to right. Asymmetry here usually means a molding or trimming issue that will repeat across the batch.
Wheels and trolley handle
Roll the loaded case on a hard floor: all wheels must touch the ground, roll quietly and track straight, with no wobble or sticking. Spin each wheel by hand and listen — grinding means a bearing problem. Extend the trolley to every stage: each stage must lock firmly, with no play or sag under load, and retract cleanly. The trolley is the most-used moving part on any case, and the most common field failure — test it harder than anything else.
Check the carry handles too: top and side handles must be firmly anchored, with no flex at the mounting points when the loaded case is lifted.
Locks
Identify the lock type first — TSA or standard — and test it as your customer will: set a combination, lock, unlock, reset, and repeat. TSA locks must accept a TSA keyway; standard locks must hold under a firm pull on the closed case. On latch-closure aluminum frames, test both latches independently: a case that holds on one latch only is a failure, not a pass.
Record the lock model in your specification. “TSA lock” alone is not a specification — the lock model is, and it is what your inspector should check against.
Interior and lining
Open the case and check the interior the way a traveler will: dividers must zip or clip cleanly, straps must adjust and hold, pockets must be stitched fully with no loose threads, and printed linings must align with the pattern — misaligned prints are visible the moment the case is opened. Smell the interior: a strong chemical odor means the lining or adhesive has not cured properly, and it will be the first thing your customer complains about.
Appearance and packaging
Check the finished case as a retail product: protective film intact, no scratches or scuffs from handling, logo plates straight and firmly fixed, and color consistent with the approved sample. Then check the carton: correct model, size and color labels, barcodes scannable, and packing that protects corners and handles in transit. Photograph any deviation against the approved sample — photos are the fastest way to resolve a claim.
How to run the inspection
Agree the inspection plan before production starts, not after goods are packed. A workable plan has three layers: in-line QC during production (the factory checks as it goes), weekly photo updates from the floor so you see problems early, and a full final inspection before loading — Kaiwei’s standard is a full inspection before loading, with nothing shipped uninspected. For larger programs, agree an AQL sampling plan and, if you want independence, a third-party inspection at the factory before loading.
Whatever the plan, put it in writing: what is checked, how many units are sampled, what counts as a fail, and what happens if a batch fails. The inspection plan is part of the program agreement, not an afterthought.
Documents to ask for
Before loading, ask for: the factory’s certificates as issued (Kaiwei’s ISO 9001 / 14001 / 45001 certificates and 9 patent certificates are shown as issued on the certifications page), the packing list against your order, and loading photos. The complete certificate pack is available to partners during onboarding. If your market needs specific test documentation, ask at quotation stage — not at loading stage — so the factory can confirm what it can provide.