Incoming Quality Control: What It Is and Why It’s Important
What Is Incoming Quality Control? Incoming quality control (IQC) is the monitoring of the quality of raw materials and/or components before the product manufacturing process even begins. If your business is sourcing products from a third-party manufacturer, IQC is critical to ensure consistent batch quality in the long term and cut costs on addressing post-production defects. This is all the more so if you are importing products or components from a foreign country and have little to no direct oversight over the production process. Why Is Incoming Quality Control Essential? Most businesses nowadays outsource the bulk of their manufacturing process and focus on assembling, branding, and marketing their products. However, the chances are that your supplier is also outsourcing the provision of raw materials, the manufacturing of components, or the packaging of the final products to various sub-suppliers. The more actors get involved in the production chain, the more important IQC becomes. Unfortunately, suppliers and sub-suppliers are often tempted to cut costs by using subpar raw materials or lower-quality components than the ones required for your products. And if you think that this is an issue with new suppliers only, think again. In our practice, we have seen many long-term and trusted suppliers trying to take shortcuts by compromising the quality of the materials or the products little by little over time. They hope that you will not notice small, incremental changes in the products from one batch to the next. This phenomenon is known as “quality fade.” More often than not, such gradual deterioration gets overlooked, and the end consumer discovers the issue before you do. And as if that were not enough, sometimes even reliable suppliers make honest mistakes. At other times, they are unable to fully grasp your quality standards due to language barriers or cultural differences. What is the only foolproof way to prevent such mishaps from happening? Rigorous incoming quality control by an independent service provider. What Happens If I Do Not Have Incoming Quality Control? If you do not monitor the quality of your raw materials or parts pre-production, you risk ending up with quality issues with the finished product later on. Addressing these problems post-production will cost you a lot more money, time, and resources. You are also likely to face shipping delays and lower customer satisfaction. You don’t have to take our word for it, either. The Jesse Garant Metrology Center estimated that the aerospace industry saves $1,000 per every $1 spent on IQC. That translates to saving a whopping $80 million in rework expenses by investing as little as $80,000 in addressing defects pre-production! How Do I Implement Incoming Quality Control? The most important thing about incoming quality control is that it must take place before the manufacturing process has begun. You should not confuse IQC with post-production protocols such as first article inspection, product inspection, or pre-shipment inspection. There are different types of IQC, and not all will be relevant to your business. It all depends on your industry, products, and quality standards. Third-Party Lab Testing Depending on your products, you may want to test the raw materials and/or the components at a certified third-party lab. Such testing is particularly important when the composition or properties of the products can affect their safety, performance, or value. Examples include jewelry, rubber tires, food, and dietary supplements. Common lab testing methods include: Testing and measurement of the products’ physical properties, such as strength, flexibility, durability, stability, and flammability. Chemical analysis, which can involve composition analysis, metals testing, trace contamination detection, and identification of unknown substances. Testing of the products’ mechanical properties, such as resistance to structural fatigue, deformation, and fracture. Regulatory testing, which tests for compliance with the relevant industry or market standards. If your products could benefit from lab testing, you should seriously consider using a professional IQC service provider. The chances are that your suppliers and sub-suppliers simply don’t have the equipment, expertise, and personnel required for the task. Can I Just Have My Supplier Collect the Samples for Lab Testing? Why should you hire an independent IQC controller when you can have your supplier collect and send the samples to be tested at the lab? Three words: conflict of interest. Your supplier has a vested interest in their materials passing the lab tests with flying colors. As a result, they are likely to cherry-pick the best samples that meet your standards. The rest of the batch, however, may be of inferior quality — and you would be none the wiser. Here’s where professional inspectors come in. They will select random samples to ensure that they are representative of the overall quality of the batch and that the lab results are reliable. Incoming Inspection of Product Materials and Parts Your products may not require full-on lab testing. Nevertheless, it is still strongly recommended that you hire a professional third-party IQC provider to inspect the raw materials and/or any components before the start of the manufacturing process. This way, you will be able to detect and take up any quality issues with the supplier early on. You will also have a choice between removing the defective parts only or replacing the entire batch altogether. In any case, you would save a lot more time and money than if you were to discover the defects post-production. It is also a good idea to re-inspect the materials or components after the issues have been addressed to ensure full compliance with your standards. Checking the Component Data Form If your products are made up of various parts, as is often the case with electronics, they probably have a component data form (CDF). A CDF lists all the critical components of your products, as well as their approved manufacturers. CDFs help ensure that the suppliers comply with your or the industry’s standards and cannot use lower-quality parts for your products. A typical CDF will contain data such as: Type or model Part number Approved manufacturers Technical data, including materials, measurements, voltages, and securement methods
Classification of Defects in Quality Control Explained
It’s not enough for a quality control inspector to merely identify faulty items in your production line. They must also categorize and report any defects they have found according to your pre-set requirements. This process is known as classification of defects in quality control, and it is crucial. Knowing what types of defects you are dealing with allows you to make informed decisions about every product batch. Depending on the severity and number of the defects, you may accept the items or return them to be reworked. Alternatively, you could destroy the products and ask the manufacturer to produce replacements. In any case, if you do not address product defects adequately, you risk losing customers, money, and even your whole business. Classification of Defects in Quality Control 101: Defect Types At this point, you might be wondering how controllers are even able to categorize the different defect types. After all, there are countless industries and product varieties out there, and each comes with its unique challenges and requirements. Can one standardized categorization system do them all justice? The answer is yes, but with an important caveat: while there are three main defect categories that are used across various industries, the classification system leaves a lot of room for customization. But more on that later. For now, let’s take a look at the three main types of defects: minor, major, and critical. Minor Defects If a defect is classified as minor, that means the item does not comply fully with the product specs but is still usable. The defect does not affect the product’s marketability and functionality and only has a minimal impact on its appearance. A minor defect is typically so tiny and insignificant that the end-user might not even notice it. And even if they do, they are not likely to return the item, request a refund, or decide against buying it. Major Defects Major defects are a different beast altogether. They are considered much more serious than minor ones. Not only do major defects cause items to depart significantly from the buyer specs, but they could also negatively impact the appearance, performance, and/or function of the faulty products. What’s more, consumers are highly likely to notice major defects and return the item, ask for a refund, and even submit a complaint to your customer service department. Critical Defects Critical effects are called “critical” for a reason. They are the most serious defect type and typically render the product completely unusable. Oftentimes, items with critical defects can also be a health and safety hazard to your staff, your customers, and even third parties. And if your products are a risk to people’s health, that means you are at risk of potential lawsuits and product recalls — to say nothing of the consequences for your brand’s reputation. Handling Defects: Acceptable Quality Limits It’s clear that if quality inspectors find critical effects in an item, you would have to discard the product or even the whole batch. However, what’s less clear is what you should do with products with minor or major defects only. That decision is entirely up to you and depends on many factors, including: The industry standards The applicable regulatory framework Your customer base Your brand image The product type You need to consider all that and more to decide how many of each defect category you are willing to accept from your suppliers. Your tolerance for defects is also known as acceptable quality levels or acceptable quality limits (AQL). That is what the quality controllers will refer to when inspecting your products. And if you are having difficulty defining your AQL yourself, you can always consult with your controllers. Most professional inspection companies will have detailed standards for both AQL and classification of defects in quality control for various product types. However, the ultimate responsibility for setting your AQL lies with you as the importer. Useful Tips for Defining Your AQL As a general rule, the more serious the defect, the lower your tolerance for it should be. Many buyers have a zero-tolerance policy for critical defects. A single fault of this type will usually cause the item to fail the inspection and get recalled. Depending on the severity of the defect and the level of risk involved, the buyer may even cancel the whole order. In contrast, there is normally a somewhat higher tolerance for minor and certain major defects. However, it is essential to set clear limits on the exact number and sub-types of defects you are willing to accept. Let your quality inspectors know that even minor defects could cause an item to fail the inspection if there are too many of them. All that doesn’t go to say that you can’t have a zero-tolerance policy for minor issues, too — especially if you are serving higher-end customers or marketing your products as exclusive or premium-quality. In any case, however, your goal should be to minimize defects as much as possible and expect a high standard of work from your quality inspectors. Classification of Defects in Quality Control: Industry Examples The same type of defect could be insignificant in some products but absolutely critical in others. Moreover, different materials are susceptible to different kinds of damage. That’s why it is important to consider the unique realities of your industry and target market when classifying defects and defining your AQL. What follows are examples of what could constitute minor, major, and critical defects in four very different industries. Electrical and Electronic Products The electrical and electronic (E&E) product category includes any item that requires electricity to function: from household appliances and consumer electronics to children’s toys, power tools, personal care items, and more. Removable, non-permanent surface marks are a classic example of what is typically considered a minor defect in E&E products. Think dirt, dust, excess glue, or anything that can be easily cleaned or wiped away. The vast majority of importers and consumers will not see that as an issue. On the other
9 Must-Have Inspection Tools in Quality Control
These are no mere gadgets to play around with: the items below are some of the most indispensable inspection tools in quality control. Whether you are doing the quality control in-house or use an independent contractor, you want to make sure that you have some or all of these at hand to test your products. Key Inspection Tools in Quality Control 1. Measuring Tape Ensuring that product dimensions are as they should be is one of the most important parts of quality control. A measuring tape is an absolute must for verifying the size of larger products and their components, as well as shipping containers and retail boxes. The strip of a good-quality measuring tape can be made of metal, fiberglass, or flexible plastic. Ideally, it should also display both metric and imperial measurement units. 2. Dial Calipers However, even the best measuring tape out there will only get you so far. But what if you need to measure the thickness of a lid, the depth of a cup, or the diameter of a plug? If you are looking to measure smaller components or finer dimensions that require a high degree of precision, you need to get yourself dial calipers. This tool can take four different types of dimension readings: outer, inner, depth, and step. What’s more, you can use dial calipers to take comparative measurements. Simply take the reference dimension, set the dial to zero, and then measure the product being inspected. The indicator will show to what extent the measurement differs from the reference value. 3. Custom Measurement Gauges Do you want to take things up a notch and save your quality inspectors a significant amount of time and effort? If this is the case, consider having custom measurement gauges made. Not only will these speed up the quality control process, but they can also provide a broader range of measurements tailored to your product’s unique geometry. Most standardized gauges will not be able to deliver accurate measurements for products with unconventional spatial dimensions and multiple smaller parts. 4. Air Gauge An air gauge can measure a wide variety of product dimensions, including: Taper Depth Diameter Thickness Inside and outside dimensions You can also use an air gauge to locate any leaks. Air gauges come in many different styles. Hand-held gauges provide quick and portable measuring solutions on the spot, whereas assembly line air gauges can automatically check large numbers of parts or products as they are assembly-processed. Bench-type air gauges work great for smaller products: all you have to do is place the component inside the air gauge to get it measured. 5. Bore Gauge The bore gauge is another multi-purpose quality inspection tool. It is similar to an air gauge, with the exception that it only measures the inside of a product. Bore gauges can measure: Degrees of taper The dimensions of parts Grooves inside the part The dimensions of any steps inside the part Bore gauges come in two types: mechanical and electronic. Mechanical bore gauges have moving components that allow them to measure the inner dimensions of a part. Electronic bore gauges, on the other hand, use electrical current to take measurements. 6. Barcode Scanner Moving on from product dimensions and on to other, equally important aspects of quality control, the first tool that stands out is a barcode scanner. Barcodes contain vital information about each product and its journey through the supply and distribution chain. Those unique combinations of different-sized miniature bars are so critical that buyers will often return entire orders if even a single barcode is inaccurate or unreadable. That’s why it is absolutely crucial to provide your quality control team with barcode scanners that allow them to verify the validity and accuracy of your products’ barcodes. Don’t forget to also provide your quality inspectors with the relevant barcode specs. 7. Defect Stickers Quality controllers use stickers to label defective parts and products during the inspecting process. Depending on the product type, different stickers may be used to mark specific defects. Defect stickers are one of the best ways to ensure that all defective items can be quickly and easily removed from the batch. That minimizes the risk of faulty products accidentally making their way further down the supply line and even to the end consumer. Stickers also save time when tallying the defective items for reporting purposes, as they allow quality inspectors to see which defects were found on which components at a glance. 8. Pantone Color Swatches Pantone is the company behind the signature Pantone Matching System (PMS), a color standardization system that serves as an excellent aid in identifying and matching colors. The PMS palette consists of thousands of colors, each of which is assigned a unique three- or four-digit number followed by the letter C, U, or M (for “coated,” “uncoated,” and “matte”). Pantone swatches can help your quality controllers detect even minor inconsistencies in the colors of your items. This is especially important in industries such as printing, design, and fashion, where the products and/or packaging must conform to specific color codes. 9. Digital Camera When it comes to quality control, a picture is truly worth a thousand words. You should ensure that your quality inspectors have a good-quality digital camera to take photos of your products. This way, you can get real-time visual updates on both the state of your items and the inspection process. As a result, you will be able to stay abreast of any defects and other issues and make informed decisions about production, shipping, and more. What’s more, photos can serve as evidence that the quality control team did indeed visit your facility and inspected the products. Unfortunately, phantom inspections can be an issue with some third-party service providers. Must-Have Inspection Tools in Quality Control: The Bottom Line Quality control is essential to the continued success of your business. However, to ensure that your inspectors can do a job, you should see that they have all the necessary tools. Of
Guide to Quality Control Procedures for Manufacturing
This guide to quality control procedures for manufacturing will help you gain a better understanding of what quality control is, as well as give you all the information you need about quality control procedures, inspections, and more. In the manufacturing industry, there are two main goals you need to meet: delivering products on time and making sure they’re top-quality. Unfortunately, making these two goals align is no easy feat. However, it’s far from impossible! But before we get to that, let’s discuss the term quality control. What is it, and why is it so important? What Is Quality Control? Ultimately, quality control is a crucial concept in any industry. Whether you’re a sweater manufacturer, or you’re in the service industry, quality control will make or break your business. Using proven techniques that help determine product and service capabilities, quality control basically enables a company to provide a product/service that’s suitable for its intended purpose to its customers. Obviously, these techniques are different for each product, and will also vary from service to service, however, the process remains the same: Recognizing the requirements for each product/service Determining whether it’s possible to meet those requirements Furthermore, quality control ensures that only top-shelf products and services are released into the world. In the same way, the ones that don’t meet the recommended requirements should be discarded immediately. What Are the Benefits of Quality Control? Most people think that quality control only benefits customers, however, that couldn’t be farther from the truth. Yes, your customers will get to buy high-quality products, but, in turn, by providing those products, you will get the following: An increase in customer loyalty Guaranteed repeat business New customers through referrals An improved market position Positive product branding A decrease in product recall In short, by ensuring product quality, you’ll get more business, and you won’t lose money due to product recall. Did you know that, in the US, one of the most frequent reasons for product recall is due to damage? Ultimately, that leads to losing millions of dollars due to faulty parts and poor quality. With that in mind, both parties (customers and manufacturers) have a lot to gain from quality control. Quality Control Procedures for Manufacturing Now that you’ve gained a basic understanding of what quality control is and why it’s beneficial for your business, let’s get into the real subject of this article: quality control procedures for manufacturing. Setting Quality Standards Some industries already have quality requirements set by an industry association, whereas others do not. For those without set requirements, the industry needs to come up with its own. Furthermore, the quality control standards will vary from department to department, but they should be objectively measurable. So, the quality standards for a customer service team obviously won’t be the same as the quality standards for a toy manufacturing company. Mainly, when establishing these standards, you should consider what you expect your final product to look like. Also, factor in the longevity of the said product. In doing so, you will have created a quality control standard. Focusing on Specific Standards It goes without saying that every manufacturer wants to ensure top quality in all aspects of their operation. But, for starters, it’s important to focus on the measures that will have the biggest effect on your profit. Obviously, these measures will vary from product to product and industry to industry. So, the first thing you need to do is set some standardized specifications. For example, a company that manufactures bed linen fabric should focus on the type of fabric they use, or rather, the thread count. If their fabrics are made from a 100% cotton/poly blend, and the thread count is set at (for example) 250, then that should be the standard. Selecting a Quality Control Method There are two ways to perform quality control checks: Full product inspection Statistical quality control (SQC). Full Product Inspection Full product inspection means checking your product at the input, transformation, or output stage against standards. The people who carry out this examination are called inspectors, and they measure the quality of your product against standards. While doing so, they also separate acceptable and non-acceptable units. After this inspection is complete, the inspectors can then look into why a product with unacceptable standards was made, and take measures to correct the mistake so it doesn’t happen again. The frequency of these product checks depends on the cost of inspection vs. the cost of no inspection. Obviously, inspecting every product is quite costly, however, no inspection can lead to a huge loss due to product defects. Ultimately, a better solution is to implement sample product inspection. Again, the size of the sample will depend on the required degree of precision, which varies from product to product. The higher the accuracy degree, the larger the sample. For example, full product inspections are done when the product in question is highly valuable or tends to get rejected at one of the production stages. Meanwhile, during a sample inspection, only the sample of work is tested and inspected for acceptance/rejection of an entire lot of products. There are two possible outcomes for a rejected sample: Discarding the entire lot Subjecting the lot to a full product inspection If the lot is subjected to full product inspection, then only the faulty parts are rejected, whereas the good parts are retained. Statistical quality control (SQC) There are two ways to perform statistical quality control: Through acceptance sampling Through process sampling Acceptance Sampling This type of sampling should determine whether or not the product in question conforms to the design specifications. Basically, a sample of the finished product is tested against the standard quality measurements, creating an acceptable quality variation limit. These variations can be due to chance or assignable causes. The acceptance sampling method ensures that the amount of defective products (if any) that makes its way to the market is kept at a bare minimum. Process Sampling During process sampling, the products are
All You Need to Know About Quality Inspection Procedures
A crucial feature of successful businesses is the quality of their products. Getting quality products is essential, but maintaining that level of quality over time is equally as important. As such, any organization looking to serve customers needs a comprehensive quality inspection procedure. A quality inspection procedure is a step-by-step process designed to check products to ensure they meet specific standards. This process is hugely important. In this article, we’ll highlight and explain the significance and procedure of quality inspections. This will help you ensure the goods you buy in China are of top quality. Why Do You Need Quality Inspections? Quality inspection is necessary to guarantee the accuracy and standard of your products. In fact, if you neglect quality checks for your business, you’re at risk of costly consequences. For instance, in 2006, Cadbury Schweppes had to recall 1 million chocolate bars due to the salmonella scare. With a top-quality inspection procedure, this could have been avoided. Here’s why you need a quality inspection procedure for your business. Build and maintain a reputation For new brands, it can be difficult to build loyalty with customers in the best of times, but if product quality is low there’s an even slimmer likelihood that they will extend brands a second chance. For this reason, your products need to have a consistent standard. Likewise, for the big names, quality inspection helps seal the trust of consumers. Cost reduction When you correctly follow a procedure for quality inspection, you save money. If you import defective goods, you’ll spend double to return and purchase new goods. These extra costs are avoidable if you check for product quality in the first place. Organizational management Even where there are quality checks, mistakes can still occur. But, this time, you can hold someone responsible instead of playing the blame game. By doing this, you effectively avoid similar incidents in the future. Profitable customers When your customers are sure of your products’ quality, they tell friends about your products. In turn, this attracts more customers and increases profits. The Procedure for Quality Inspection You already know that quality inspection is essential. Now, let’s discuss the whole process. What needs to be checked? When and where do you need to do these checks? These are some of the questions will answer. Truthfully, it’s best to have quality checks all through the production cycle. That is because mistakes can occur at any point. Some of the times you need your quality inspection procedure include: Before the production process Before production, every manufacturing element needs to be inspected thoroughly. The devices, the people, and other resources and materials that produce goods need quality checks. You start reviewing from the pre-production stage until about 20% of production is complete. For those looking to import products in bulk, this is the same as pre-shipment inspections. Let’s consider a scenario where your primary product is a pie. Before production, your quality inspection procedure should check the raw materials and other devices. After that, you can proceed to make one pie, which you must inspect well. If the final product is right, you can move to full production while still reviewing. Throughout the production process While the production process is ongoing, some unintentional defects may occur. Performing quality checks during production can help you detect the mistakes quickly and avert costly errors. When you discover errors during production, you can quickly make adjustments to the process. For example, if you produce milkshakes, and you discover some dirt particles during production. You can easily pause and clean the machinery before you continue production. After production When you’re producing goods, you should carry out timely checks. For instance, after a day’s production of milkshakes, you should check all products at random. That way, you’ll have the chance to discover any errors which you can avoid in future production. On the other hand, if you produce all goods at once, you ought to carry out thorough checks of every single product. Before and after distribution After producing goods, you need to distribute to make sales. Whether you’re selling directly or supplying through shipments, you must follow a quality inspection procedure. For instance, if you’re shipping goods to another country, there are ISO standards to follow. You can run final checks on the goods and the cargo before you distribute them. When goods are in the market, you can still run quality checks. You can ask customers for reviews to check if the final products meet the standards. Now that we know the periods in which we can inspect quality, let’s discuss the process. There are some things you must do to ascertain the quality of the goods you’re bringing in from China. Here are some of the keys: Determine your standards The first step for any quality inspection procedure is to establish the standard requirements. That way, you know what to look out for when checking your products. Furthermore, each department involved in the exportation and distribution process should have different standards. In many cases, there are traditional associations that govern the standard for different industries. For example, the health industry has organizations like W.H.O, which set the standard. Additionally, these standards need to be reasonable and measurable. Perfect examples of standards for your customer support team can be: Resolving a customer’s request within 2 hours Answer all customer emails before closing time. Establish the crucial standards Indeed, you want your whole production process to be of top-notch quality, but you need to determine the essential standards to execute. That way, you can maintain quality quite effectively. Also, you can decide which aspects of the business to channel efforts to. Let’s say you manage a banquet hall; keeping the room well-lit is an excellent standard, but attending to customer’s requests is of utmost importance. It’s better to channel your focus to customer satisfaction and fix the lights later. This school of thought can also be applied to the importation and exportation of products. Manage your operations Even
4 Reasons Product Inspection Is Not the Same as Product Testing
If you are a foreign buyer who has started importing products from China, you might find quality control processes a bit hard to understand. It is quite common for our customers to mix product inspection and product testing, since both terms sound so similar. After all, both indicate a process of quality assurance for certain products, right? While that is true, there are big differences between the two. Why Knowing the Difference Between Product Inspection and Testing Is Key As a buyer, you need to be very careful about the products you import. You need to know that they have undergone the proper quality control measures and the provider has delivered everything up to specifications. Our company specializes in offering third-party product inspection services and quality control. We know how important it is to be familiar with the different processes and how buyers benefit from each. Product inspection and product safety are in fact different stages of an overall quality control process. In this article, we will outline the key differences between the two. We will also present the benefits each process offers to you as a buyer. First, let’s take an in-depth look at what the two terms represent. What Is Product Inspection? Product inspection is a process of determining whether the manufactured goods and products are up to your specifications and requirements. This process is conducted at the factory that is manufacturing your products. Its main purpose is to find and fix any issues and quality defects before delivery. Inspection teams analyze the functionality, appearance, and overall quality of the products, looking for flaws or details that are not up to specifications. There are a variety of methods for product inspection, with most of them including analysis of a random number of items from the overall order. What Is Product Testing? Product testing, also known as lab testing, is a controlled process that is conducted by a third-party laboratory and not the manufacturer’s plant. The testing can be done on-site, but it must be a part of a third-party inspection process. However, this does not happen often, since product testing needs to be performed in a different, more controlled environment. When it comes to importing goods, product testing is not always necessary. It all depends on the type of product and the regulations you need to deal with. Goods that have gone through product testing obtain certificates that prove their quality and performance. Certain industries (food and beverages, chemical substances, etc.) require independent lab testing in order for a product to make it to the market. The 4 Main Differences Between Product Inspection and Product Testing Now that we have established what product inspection and product testing are, we can get down to the details. Even though both processes look and sound similar, we can point out four key differences between them. First of all, the entity that conducts the quality check is different in each process. Second, the exact time when each quality check is performed is different as well. Next, both processes check a different number of units in order to perform the needed tests. Finally, product inspection and product testing offer different benefits to you as a buyer. In the following paragraphs, we will take an in-depth look at each of those differences. In the end, you will understand why product inspection is not the same as product testing. Also, you will see the benefits of hiring a professional third-party product inspection company to ensure the quality of your imported goods. 1. Who Conducts the Process As we already mentioned, one of the major differences between product testing and product inspection is the party who conducts the check. When it comes to product testing, it is performed on-site in the manufacturing facility. Some factories employ full-time inspectors whose sole job is to ensure the quality of all production. In other cases, third-party personnel do the job. It is not unusual for the buyer to send their own inspectors to ensure all goods are up to specifications. Product testing is almost exclusively conducted by certified third-party laboratories that operate in controlled environments. The manufacturer sends out samples to the lab, which in turn runs independent checks to make sure the products fulfill all requirements set by the buyer and any concerned parties. Only certified centers are authorized to perform product testing and issue certificates. 2. When the Process Is Conducted Another key difference between the two quality checks can be found in the time when they are performed. The final product inspection, also known as pre-shipment inspection occurs when the manufacturer has completed 80% of your order. It is the bare minimum when it comes to consumer products. As you can guess, doing an inspection this late in a production process can lead to problems. Since it happens quite late, there is often not enough time to address any issues with the production. The best time to begin product inspection would be when around 15% of the requested units are ready. That would give enough time to the manufacturer to go back and fix anything that is not up to specifications. When it comes to third-party product testing, best practices dictate it should be performed at two key stages. The first testing should be conducted on samples right before mass production begins. After that, an additional test should be done after production has already started. Running a test right before and during the actual manufacturing process ensures that defects get discovered and fixed before it is too late. A general rule of thumb when dealing with Chinese manufacturers is to always request a sample before mass production begins. On the one hand, you will make sure the product is what you requested. On the other, you will be able to send it for independent product testing at a certified lab. 3. Number of Units Checked Product inspection and product testing differ in the number of units undergoing the quality check. With product inspection, checking only
50 Quotes About Quality That Sum Up Its Importance
Good quality is the single most important aspect of any product that you consume. In this day and age, increasingly more people make sure that the products they use meet certain standards, and so should you. Below, we’ve gathered some quotes about quality to show you just how important that aspect is. Let our choice of quotes about quality inspire you to always seek the best in everything. Never settle for less than you deserve, and always make sure to prioritize quality. The Most Famous Quotes About Quality to Promote Improvement #1. “Quality is more important than quantity. One home run is much better than two doubles.” — Steve Jobs #2. “Sometimes when you innovate, you make mistakes. It is best to admit them quickly and get on with improving your other innovations.” — Steve Jobs #3. “Be a yardstick of quality. Some people aren’t used to an environment where excellence is expected.” — Steve Jobs #4. “If you can’t explain it simply, you don’t understand it well enough.” — Albert Einstein #5. “The definition of insanity is doing the same thing over and over again and expecting different outcomes.” — Albert Einstein #6. “Without changing our patterns of thought, we will not be able to solve the problems that we created with our current patterns of thought.” — Albert Einstein #7. “Quality questions create a quality life. Successful people ask better questions, and as a result, they get better answers.” — Tony Robbins #8. “The way we communicate with others and with ourselves ultimately determines the quality of our lives.” — Tony Robbins #9. “A real decision is measured by the fact that you’ve taken a new action. If there’s no action, you haven’t truly decided.” — Tony Robbins #10. “It is quality rather than quantity that matters.” — Lucius Annaeus Seneca #11. “Be passionate about solving the problem, not proving your solution.” — Nathan Furr #12. “That which we persist in doing becomes easier — not that the nature of the task has changed, but our ability to do it has increased.” — Ralph Waldo Emerson #13. “Nothing great was ever achieved without enthusiasm.” — Ralph Waldo Emerson Quotes About Quality to Inspire Hard Work and Dedication #14. “Quality is never an accident; it is always the result of high intention, sincere effort, intelligent direction and skillful execution; it represents the wise choice of many alternatives.” — William A. Foster #15. “The starting point of all achievement is desire.” — Napoleon Hill #16. “The most dangerous kind of waste is the waste we do not recognize.” — Shigeo Shingo #17. “Quality needs to be constantly improved, but it is just as necessary to make sure that quality never deteriorates.” — Shigeru Mizuno #18. “Every action is an opportunity to improve.” — Mark Graban #19. “More business is lost every year through neglect than through any other cause.” — Rose Fitzgerald Kennedy #20. “Almost all quality improvement comes via simplification of design, manufacturing… layout, processes, and procedures.” — Tom Peters #21. “Quality means doing it right when no one is looking.” — Henry Ford #22. “Quality is everyone’s responsibility.” — W. Edwards Deming #23. “The quality of life is more important than life itself.” — Alexis Carrel #24. “The quality, not the longevity, of one’s life is what is important.” — Martin Luther King, Jr. #25. “Men acquire a particular quality by constantly acting a particular way… you become just by performing just actions, temperate by performing temperate actions, brave by performing brave actions.” — Aristotle #26. “Quality is not an act. It is a habit.” — Aristotle #27. “The quality of our expectations determines the quality of our action.” — Andre Godin #28. “Make the workmanship surpass the materials.” — Ovid #29. “Many of life’s failures are people who did not realize how close they were to success when they gave up.” — Thomas A. Edison #30. “Always do things right. This will gratify some people and astonish the rest.” — Mark Twain Motivational Quotes About Quality to Keep You Moving Forward #31. “Persistence is the twin sister of excellence. One is a matter of quality; the other, a matter of time.” — Marabel Morgan #32. “If a thing’s worth doing, it’s worth doing well.” — Chinese Proverb #33. “A bad workman blames his tools.” — Chinese Proverb #34. “The ideas of control and improvement are often confused with one another. That is because quality control and quality improvement are inseparable.” — Ishihara #35. “Good quality is never achieved by accident.” — Ishihara #36. “One of the rarest things that a man ever does, is to do the best he can.” — Josh Billings #37. “The quality of a person’s life is in direct proportion to their commitment to excellence, regardless of their chosen field of endeavor.” — Vince Lombardi #38. “Eventually everything connects — people, ideas, objects. The quality of the connections is the key to quality per se.” — Charles Eames #39. “Anything worth doing is worth doing poorly until you learn to do it well.” — Steve Brown Quotes About Quality to Help You Make Better Choices #40. “Quality is the best business plan.” — John Lasseter #41. “Everything can be improved.” — C. W. Barron #42. “There is no such thing as a perfect method. Methods always can be improved upon.” — Walter Daiber #43. “By the work one knows the workmen.” — Jean De La Fontaine #44. “Do or do not… there is no try.” — Yoda #45. “Quality is never an accident; it is always the result of high intention, sincere effort, intelligent direction and skillful execution; it represents the wise choice of many alternatives.” — William A. Foster #46. “Anything worth doing is worth doing right the first time.” — Unknown #47. “Total quality management is a journey, not a destination.” — Unknown #48. “Higher quality costs less, not more.” — Scherkenbach #49. “Consumers, by seeking quality and value, set the standards of acceptability for products and services by voting
12 Dos and Don’ts of Pre-Shipment Inspections
Pre-shipment inspections are a must in the modern world. With so many different products crossing oceans and reaching into your homes, you can never be too sure if the product you’re getting is safe or not. In addition, if you run a business, you will need to make sure that your products are up to the standards you’ve set for yourself. Nowadays, entire companies can get shut down overnight just because of one bad shipment. Obviously, even some of the most seasoned business owners aren’t too sure about what makes a good inspection. However, businesses with high standards, like our own Jonble, will always strive to provide the best, most detailed pre-shipment inspections out there. And in order to do that, we follow a list of 12 dos and don’ts about inspecting goods and products. This list, which we will cover in a bit, contains the most important details you should pay attention to when considering a pre-shipment inspection. But before we move on to the list itself, we need to establish what pre-shipment inspections are and why they’re important. What Is a Pre-Shipment Inspection? A Pre-Shipment Inspection (PSI) is a type of quality control method. It helps you make sure that the quality of goods you receive from suppliers is up to the highest of standards. Let’s say that you’ve just finished manufacturing 100% of your units that you plan to ship. In addition, you’ve packaged about 80% of them. At that point, an inspector is sent to your factory in order to perform a number of different quality checks. Normally, they will check for the following: Are the packages and labels in order? Do the products look in order? What are the dimensions of each product? What are some of the other physical requirements of the product? How well do they handle functional and drop tests, as well as other types of testing? Are the barcodes valid? Of course, each inspector has to follow a certain set of rules before they start pre-shipment inspections. That way, you, the manufacturer, will be safe from any inspection malpractices. The investigator should take these rules into consideration: They must be transparent They mustn’t discriminate on any grounds Confidential business information should not be compromised during the inspection They must avoid causing any delays Their price verification should follow a set of its own rules (i.e. comparison with similar products) Their inspection agency must establish an appeals procedure. Since an inspector will pick products at random to check, PSIs are also called final random inspections, or FRI. If you want to learn more about random inspections at Jonble, have a click right here. Why Are Pre-Shipment Inspections Important? How many times has it happened to you — you buy a car radio with Bluetooth and it doesn’t connect, or you buy a folding chair and the fabric appears snapped in the packaging? There are even horror stories out there of people buying a can of soda only to find a dead frog inside. These should be the obvious reasons behind the importance of PSIs. They will ensure that your products don’t lack anything and that they are ready for shipping. There are some important benefits to a PSI. Some of the most crucial ones include: Verifying product quality so that you (or your buyers) don’t deal with defective units Making sure that your factory made the product exactly per your specifications Avoiding defective product returns that might negatively affect your company’s image Making sure your products are safe and don’t contain any health hazards. Reducing the risk of smuggling illegal substances Checking all of the relevant paperwork for any mistakes The Dos and Don’ts of PSI: Our List Now that you understand the ins and outs of PSIs, we can move onto our list of dos and don’ts. The Dos DO Have a PSI Checklist You will need a detailed PSI checklist to provide to your inspector. It will help them keep an eye out for any defects and mistakes. More importantly, you can make sure that each product is being made according to your specifications. DO Visit Your Factory Visiting your factory gives you the opportunity to see if there are any problems early on. However, you don’t want to do it too early, as that might halt production. Instead, organize pre-shipment inspections when production reaches around 80%. That way, you will have the time to fix any issue without losing extra time on the production of new, proper units. DO Check Product Quantity When doing a quantity check, you will need the customer’s specifications. You should have more than the exact number of units they are looking for. In addition, check for the delivery deadlines; if you’re running out of time, validate the customer’s specifications and act accordingly. DO Perform Visual Inspections In shipping, we have a term called Acceptance Quality Limit or AQL. When you’re checking your products with your naked eye, assess any external damage, and check for defects. Anything that falls under AQL guidelines is ready for shipping. DO Select and Check Samples When doing a PSI, you don’t have to go over every product individually. Instead, pick a sample product or a few and test them. Depending on the inspection levels, you can decide whether you want to ship the products or not. DO Compliance Checks You set the rules for making your products, so it’s only logical that you want to test them before these items ship. In addition, check to see if they fit the customers’ requirements. These usually include tags, labels, packaging, manuals, as well as quantity. DO Safety Tests Depending on what kind of product you manufacture, it will need to pass a series of safety tests. Said tests will ensure that your product won’t harm the customer or damage the environment. For example, if you make chemicals, they will need extensive lab testing. Electrical appliances need performance testing, while other objects need to pass tests of durability so that they
Debunking a Myth: Why the Quality of Chinese Products Isn’t Poor
For as long as people have been buying products from China, there has been this running myth that it’s all cheap, low-quality stuff. However, what some buyers don’t understand is that the quality of Chinese products has improved immensely over the last few decades. In fact, it has never been easier than it is now, to buy superb products and materials from China. Here’s why. How the Quality of Chinese Products Evolved Over the Years Going from cheap, plastic products to high-quality equipment has not been an easy process. But here’s how China has managed to overcome its bad reputation, and come out the other side. 1. Advancements in Technology Back in 2015, China opened its first unmanned factory, which was a huge step toward dropping its defect rates. Thanks to the computer-controlled robots, the company from Dongguan city has been able to manufacture much better products than ever before. That’s because robots rarely make mistakes, and the robotic arms can work continuously. Of course, the unmanned factory is a somewhat extreme example of technological advancements. But over the last few decades, China has been following Japan’s example and investing a lot in its equipment. Nowadays, there are more machines and devices that can weed out the good from the faulty. In turn, the quality of Chinese products has gone up, and so has customer satisfaction. 2. Higher Labor Costs As China’s economy saw massive growth, so did the labor costs. In fact, in the past 10 years, workers have started earning more than 60% of what they used to, which is really impressive. But what does that mean for the importer? Well, given that labor costs are now higher, Chinese manufacturers have had to improve and optimize their production processes. One good practice that they’ve taken up is to pay more attention to better quality right from the start. That way, they were able to reduce mistakes, and almost eliminate manual rework. 3. Experience and Practice As with anything else in the world, getting product quality to where it is now was a long and bumpy road. Thankfully, over time, Chinese manufacturers started taking notes from other companies on how to make their products better. One of the first things most companies implemented was a better factory layout that would improve efficiency. Also, manufacturers put a huge emphasis on making their organizational processes better. 4. Quality Control Way back when, importers had issues with Chinese suppliers because they weren’t getting what they paid for. That’s because quality control was pretty much non-existent, and it was solely on the importer to hire someone. Also, quality standards were much lower a couple of decades ago. In addition to that, a lot of suppliers would oversell their abilities because they really wanted the job. However, times are changing pretty fast, and Chinese companies seem to have a much better understanding of what’s expected of them. So there’s a slim chance that you, as an importer, can get a product that’s not up to your standards. Another thing that has changed the game is that importers can nowadays hire reliable companies like Jonble to do their quality control. By hiring a third-party expert, your final product will undoubtedly be much better. 5. Competitive Markets There was a time when China was the biggest, as well as the sole, supplier for countless products and materials. So they didn’t really have to worry about their quality, or meeting deadlines. But as the world economy began changing, more countries, like Japan, started exporting their products. Soon, their vehicles, machinery, and plastic equipment would hit markets worldwide, leaving China behind. One of the reasons that made Japan do so well was because they began exploring ways to improve their quality. By re-evaluating their organizational processes, Japan was able to export high-quality products, at lower prices. Of course, China took note, and the quality of Chinese products has not been the same since. Now, their materials and exports are some of the best in the world and are on-par with other giants. Why You Should Be Importing From China We hope that we’ve settled any doubts or questions that you had about the quality of Chinese products. But if you’re still not convinced about importing from China, here are several reasons that might change your mind. 1. Affordable Prices Most importers enjoy the Chinese market because of its low prices. The materials, as well as the labor costs, are much lower in China than they are in most parts of the world. Also, some of the unmanned factories that we mentioned earlier can deliver products at more affordable prices. But that’s not to say that you should always go with the lowest bidder. Remember, at the end of the day, you will get what you pay for. So don’t expect to low-ball a price on a product, and get the superior quality that you expect. That’s just not how that works. In addition to the basic labor and material costs, you should also include a quality inspection in your budget. It’s an essential part of the process and the only one that guarantees that you’re getting what you paid for. 2. Original Equipment Manufacturers One of the biggest benefits of buying products from China is that you can go straight to the original equipment manufacturers (OEMs). By skipping the middleman, you can save a lot of money and time, and go directly to the source. Also, you can buy goods from China in bulk, which will not only be cheaper but will come with lower taxes as well. One of the best things about Chinese manufacturers is that they don’t require you to hold any special license or permit to export. All you have to do is to educate yourself on trade and customs regulations. There’s another huge plus when it comes to importing from China, and that’s being able to have direct control over the distribution model. It’s completely up to you where and how you’re
5 Main Types of Inspections in Quality Control
While purchasing products from an overseas manufacturer is a valuable asset when you expand your business overseas, without quality control inspections, you’ll always be left wondering whether the products you purchased meet your standards. That’s where quality control inspection companies like Jonble come in. You might not be able to fly overseas to oversee production, however, quality control inspectors can be your eyes and ears. Not only that, but many quality inspectors often specialize in certain types of inspections that can benefit your business in different ways. We know you might be wondering what quality control inspections you need to undertake when you’re sourcing products from overseas, and we’re here to help. So, let’s take a look at the five main types of inspections in quality control, how they’re performed, and when you should consider using them. 1. Pre-Production Inspection (PPI) The very first inspection that takes place following a purchase order is known as a pre-production inspection. During a PPI inspection, the quality control inspector will visit the site of your supplier to evaluate the quality of raw materials, components, and other preparations they are making for the manufacturing process. A typical PPI inspection checklist includes, but is not limited to: Verifying the raw materials and their condition Inspecting planned storage for your products Inspecting a supplier’s production readiness and quality plan Inspecting the function, size, and measurement of raw materials and other components Making the required reliability and safety tests One of the main reasons why retailers use PPI inspections is to ensure that the supplier they’re purchasing from is using the raw materials and components outlined in the contract. It’s an unfortunate truth that many unreliable suppliers may try to use cheaper raw materials and components to save themselves money. However, if these raw materials don’t work with your product, then it’s you that has to deal with customer returns, complaints, and potential safety hazards. 2. First Article Inspection (FAI) Once production has started at a supplier’s site, then a first article inspection can be conducted. With an FAI inspection, your quality control inspector will inspect the first mass production run of your product from both the factory floor and the design documents. A typical FAI inspection checklist includes, but is not limited to: Verifying the product matches the design documents Verifying the supplier follows the requested process and material specifications Making technical notes about the nature of manufactured products Most purchase contracts require that the retailer carries out an FAI inspection, which is why they’re one of the most common forms of quality control inspections. FAI inspections are also required following any engineering, materials, parts, manufacturing, or tooling changes to ensure that there have been no negative effects on your products. 3. During Production Inspection (DPI) A during production inspection takes place once 20-50% of your product run has been completed and packed. During a DPI inspection, a quality control inspector will inspect the completed product to ensure that all processes are being followed to the agreed standard. They’ll also look to identify any product deviations or issues early in the manufacturing process. A typical DPI inspection checklist includes, but is not limited to: Verifying the production and quality plan Inspecting storage conditions Inspecting packaging, labeling, and barcodes Conducting reliability and safety tests Inspecting semi-finished products DPI inspections are useful as a quality assurance measure as it ensures that the quality of the products in production is the same as the one you received as a sample. It also gives you chance to make any necessary adjustments and corrections before the production run has ended, which can save you valuable time and money. If defects have been identified, knowing the percentage of finished products with defects also ensures that you have time to plan for them before they are shipped to you. 4. Pre-Shipment Inspection (PSI) Also known as a final random inspection, a PSI inspection makes sure that the supplier has manufactured your products to your specifications and packed them as required by your purchase contract. This will be conducted based on a random sample of products taken from the shipment, and as such, it’ll only be performed once the manufacturing run is complete and at least 80% of the order has been packed. A typical PSI inspection checklist includes, but is not limited to: Verifying the safety and function of manufactured products Verifying the quality of products and organizing any price adjustments Verifying the order has been produced to the standards set out in the purchase contract Inspecting the product packing, labeling, and shipping marks The biggest strength of organizing a PSI inspection is that because products are taken as a random sample from the order, you get an accurate view of the order without needing to inspect every product. Also, safety and functionality tests conducted as part of a PSI inspection will help to identify faulty products, which you can then refuse to pay for. 5. Container Loading Inspection (CLI) The final quality control inspection type is a container loading inspection. Unlike the other inspections, this takes place at a supplier or forwarder’s warehouse. During a CLI inspection, your quality control inspector will supervise the loading of shipping containers to ensure that your order has been packed correctly. A typical CLI inspection checklist includes, but is not limited to: Verifying the correct goods have been loaded in the correct quantities Checking packaging for physical and environmental damage Performing a random spot check of products Recording loading conditions, seal numbers, and departure times Supervising the loading process to minimize damage and breakages A CLI inspection is your final chance to verify the quality of the products that you’ve ordered and reduce the risk of damage during transit, which can save you time and money when your order arrives. It also gives you the chance to stop any damaged products that were missed in earlier inspections from being shipped and sold, helping to save your brand image and reputation. Quality Control Inspections from Jonble