Replacing our current modular sofa supplier — foam sectional modules, 15,000 pcs/year

Our current supplier for frameless modular foam sofa pieces has had recurring quality issues — inconsistent foam density between batches and cover seams that don't hold up — so we're qualifying an alternative manufacturer for the programme. Product: boneless/no-frame modular sofa units, foam or memory foam fill, polyester fabric cover that's fully removable and machine-washable, square arm style, cushion-back design. We need corner, armless and chaise modules available in a shared fabric and foam spec so customers can mix and match without visible differences between pieces. Volume: about 15,000 pieces per year across the module types, released in four call-offs. The switch is about consistency and quality control, not price — we need a supplier who can hold a tight tolerance on foam density and seam construction batch to batch. Requirements: RoHS compliance and BS 5852 fire-resistance documentation per fabric/foam combination, plus your quality control process for checking foam density and seam strength before shipment — this was the specific failure point with our current supplier. Packaging: compressed/vacuum-packed per module for parcel-level shipping to end customers, palletised for the bulk freight leg to our warehouse. Delivery: DAP our Rotterdam warehouse. In your proposal, please cover: EXW and DAP pricing per module type at this volume, your standard lead time and how consistent it stays across repeat orders, your QC process for foam density and seam consistency, and whether you can provide a small paid trial batch before we commit to the full switch.