A bulk shipment is rejected because the logo is the wrong shade, the cable is a lower rating than the sample, or the box insert changed. None of those defects appeared at the last inspection; they appeared because approval was given at the wrong stage. Gates exist to make approval an event with evidence, not an email.
This guide is part of our Charger Quality & Inspection. Read the full topic guide for the decisions that come before and after this step.
Why bulk rejections start at sample stage
When the approved reference is vague, the factory reinterprets it during production. The remedy is to approve a physical object at each stage where the product changes, and to record what was approved. Each gate narrows the remaining uncertainty: the electrical design, then the branding, then the packaging, then the production intent.
Gate 1: engineering sample
The engineering sample proves the electrical and mechanical design: output behaviour, port detection, thermal performance and fit. It is usually unbranded and may be built before the final enclosure texture and print. Approval at this gate means the design works; it does not mean the product is ready to sell.
Gate 2: branded sample
The branded sample adds logo, colour, finish and the final enclosure appearance. This is where cosmetic expectations are fixed: the shade, the print position, the surface texture and the fit of the assembled parts. Approval should be against a physical unit retained as a reference, not against photographs.
Gate 3: packaging proof
The packaging proof confirms the retail box, insert, print colour, language versions, accessories and manual. It should be assembled and, where relevant, drop-tested in the proposed structure. Packaging is the most common source of a late objection because it is approved late; moving it to a formal gate removes that risk.
Gate 4: golden or pre-production sample
| Gate | What it proves | Evidence |
|---|---|---|
| Engineering sample | Electrical and mechanical design | Test results and assembly check |
| Branded sample | Appearance and branding | Retained physical reference |
| Packaging proof | Packaging structure and print | Assembled box and drop test |
| Golden sample | Production intent, all components final | Signed unit retained by both parties |
The golden sample is the reference production is measured against: the final enclosure, print, cable, accessory set and packaging, with the certification marking and label as they will ship. Both parties should retain one and reference it in the order.
What each gate must produce as evidence
Each gate should produce a signed record: what was approved, the version or revision it corresponds to, the date, and the outstanding items with their limits. Photographs support the record but do not replace a physical reference, because colour and texture do not survive a photograph or a screen.
Sign-off documents and version control
Version control matters when components or artwork change. The approval record should reference the BOM revision and the artwork revision, so that a later substitution can be checked against what was approved. Where a change is necessary after the golden sample, the change should be approved in writing and a new sample issued.
Retention of approved samples
Both the factory and the brand should keep the approved sample for the life of the programme, stored so that colour and surface do not degrade. The sample is the reference for an incoming inspection dispute, and programmes without one tend to resolve such disputes by negotiation rather than by measurement.
Where the time actually goes
Most of the elapsed time between gates is transport and feedback, not production. A sample that ships by express and is approved within two days costs less calendar time than one that travels with a consolidated shipment and waits for a weekly review meeting. Decide the approval owner and turnaround before the sample ships, not after it arrives.
Approval-gate checklist
- Four gates defined with owners and dates
- Evidence required at each gate agreed in advance
- Physical reference retained by both parties
- Approval record linked to BOM and artwork revisions
- Change procedure defined for post-approval modifications
- Golden sample referenced in the production order
Speeding up approval without lowering the bar
Approval time is mostly communication, and it can be compressed without reducing the evidence. Name a single approver on the brand side rather than a committee, agree the acceptance criteria before the sample ships, and decide in advance what will be checked against the retained reference. Where the programme is a re-badge of an existing platform, the engineering gate can often be closed from earlier records, leaving the branded and packaging gates as the substantive checks. Two practical habits make the biggest difference: photograph the sample next to the approved reference under the same lighting, and record the approval against the BOM and artwork revision in the same message. Both reduce the chance that a later change is approved informally and discovered at inspection.
FAQs
How many sample rounds does a charger project need?
Four approval gates are typical for a new product, and fewer when the programme is a re-badge of an existing platform where the electrical and mechanical design is already approved.
What is a golden sample?
The final approved unit, built with production components and packaging, that defines what the shipment must match. It is signed and retained by both parties.
Who keeps the approved sample?
Both sides. The factory uses it for production reference and inspection; the brand uses it to resolve a dispute about conformity.
Next step
Wecent Group applies engineering, branded, packaging and golden-sample approval gates, with branded samples produced in two to three days where the platform allows. Send your approval process to the contact page. Related reading: OEM project sequence, inspection gates, sample shipping and customs and certification project plan. External references: ISO 9001, ISTA packaging testing, IEC standards, EU CE marking, FCC equipment authorisation and IEC standards.
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