Understanding Inspection Methods for Chinese Suppliers
What are the Methods of Inspection? Online marketplaces like Amazon and Walmart have provided access to thousands of new resellers looking to make their mark on the retail industry. The backbone of a successful reselling business is partnering with reputable suppliers to source quality products. For many, the process of finding the right suppliers is difficult when the factories are on the other side of the globe. Language barriers, time zone differences, and cultural nuances make it all but impossible to manage the fulfillment process from sourcing to shipment. The cost of using a third party inspection company is minimal compared to the potential savings of ensuring that your suppliers are reputable and are performing quality work. In a domestic factory, every step of the process is checked for quality. From initial production to preloading the containers, a third party inspection company can be your eyes and ears in foreign factories. 1. Initial Production Check An initial production check is the first step in your quality control process. Occurring at the beginning of a production cycle, an inspector checks the materials and processes used in the plant against the master samples and prototypes previously provided. An initial production check is important for identifying and correcting errors before it is too far into the production cycle. It can also protect you from being undercut with cheaper materials than previously discussed. Initial production checks also serve as a metric to evaluate your supplier’s ability to handle production volume. While we would all like to believe in the honesty of those we do business with, an underprepared or understaffed factory will only continue to cause problems and cost money down the road. Early intervention when there is a problem is your best line of defense. 2. During Production Inspection Our inspection services are not limited to finished products. We will happily inspect raw materials and early production processes to ensure that everything is in line from the beginning. Production inspections are sometimes necessary to avoid rejecting entire batches. It can be necessary to complete routine inspections on raw materials when working with new suppliers or those who have demonstrated questionable quality in the past. This type of inspection can save a lot of time by identifying key issues early. And time is essentially another way of measuring profitability, so your company is ultimately saving money by saving time. The timing of a production inspection is important. Just like anyone learning a new skill or, in this case manufacturing a new product, the early samples will be of lower quality. As the manufacturer perfects their skill or process, the quality of work will increase relative to their experience. Samples taken too early into a new production run will not represent the average quality of the finished product. There are some notable exceptions depending on production times for different products, but most orders should be inspected between 20 – 30% complete. If you wait too long to conduct a production inspection, likely, the majority of the lot is complete before you have had a chance to identify any flaws. Waiting too long into the production cycle can render the inspection useless and cost the supplier and buyer more money in the long run. Read more: https://www.jonble.com/during-production-inspection/ 3. Pre-Shipment Inspection Pre-shipment and container loading inspections occur on finished products. This type of inspection is too late to identify quality issues with raw materials or production processes. However, it is still invaluable in making sure that quality product is what leaves the port. Pre-shipment inspections are detailed audits that inspect finished products for quality and description matches for size, color, weight, and functionality. This inspection also checks to ensure that the product inside the cartons matches the labeling on the outside of the cartons. We check to make sure that all products are labeled in accordance with global trade regulations to prevent delays in export or import. The pre-shipment inspection occurs when the product is approximately 80% complete and loaded onto the container. 4. Production Monitoring Inspections timed at specific intervals during production are useful to identify potential and existing problems. But what do you do when these spot checks or one-day inspections continue to turn up concerns? While it could be a sign that it is time to find a new factory, more detailed production monitoring can help smooth out the problems. This type of inspection is also warranted on large-scale projects where there are plenty of opportunities for errors to occur in between traditional production spot checks. The biggest advantage of continuous production monitoring is the real-time feedback as changes are implemented. There is a possibility that the factory will see this type of monitoring as an attempt at micro-managing their production. These types of negative feelings can create conflict between the factory and the inspector. The best way to prevent these issues from impacting your business relationship with the factory or the inspector is to be open and upfront about your intentions for using production monitoring. While you may not prevent all conflict, being open about using continuous production monitoring can improve the situation. Production monitoring can be done for specific intervals of time or on an on-going basis. The costs associated with this type of inspection are significant due to the labor required by the inspector. But compared to hiring a direct employee in another country, production monitoring offers the next best option when you need to be more hands-on at the factory. 5. Container Loading Check When completed merchandise is ready to ship from the factory to your warehouse in the United States, the manufacturer loads the product onto a sealed container and transports it to the dock to be loaded on a vessel. The container goes through export customs at the dock and must meet legal regulations to export and be accompanied by all appropriate paperwork. Once released, your container travels by ship until it reaches the port in the United States. It comes off of the ship and passes
Quality Assurance and PPAP Compliance
Often, we thoroughly research automotive brands for system defects and recalls. While these services are generally unavoidable, a lot goes into ensuring minimal system failures and that a vehicle on the market is safe for public use. Here, we look at how PPAP standards ensure quality and consistency in their product. In short, PPAP stands for Production Part Approval Process and was developed by the Automotive Industry Action Group (AIAG) to encourage uniformity in terminology and forms on production line vehicles. A Brief History To create a standard manufacturing method and streamline the automotive industry, AIAG released the PPAP protocol in 1993. The first PPAP manual was developed in association with Ford, Chrysler, and General Motors. PPAP guidelines outline standard production elements, including project requirements, engineering principles, common terminology, and standard forms. This automotive supply chain process of approvals works to establish confidence in component suppliers and manufacturers. Updated PPAP documentation maintains a record for engineering design that is mutually understood by both the customer and the manufacturer. While PPAP is known throughout the automotive industry, other manufacturers, like the aerospace industry, have also adopted this process to ensure that specifications are met. This process, paired with great quality assurance, like that offered by Jonble, can help reduce the risk of a product malfunction or failure. The PPAP Package The manufacturer will typically compile a PPAP package, which includes all of the documents needed for a formal certification from the supplier and formal approval from the customer. The package is acceptable whether it is stored and delivered electronically or as a hard copy in a binder. The PPAP package draws from the Advanced Product Quality Planning (APQP) process used when developing new vehicles or component systems. The package also includes elements required for obtaining approvals, the customer’s purchase order and submission levels, and any other customer-specific requirements. PPAP Levels of Submission When a customer requires PPAP compliance, they usually also note the submission level. The customer will provide the elements that need to be included at each level on the purchase order. The customer can require any of the following levels: Level 1 – Part Submission Warrant (PSW) only submitted to the customer Level 2 – PSW with product samples and limited supporting data Level 3 – PSW with product samples and complete supporting data Level 4 – PSW and other requirements as defined by the customer Level 5 – PSW with product samples and complete supporting data available for review at the supplier’s manufacturing location Elements in a PPAP Checklist The current release of the AIAG PPAP manual is in its fourth revision. There are 18 required documents, which are commonly referred to as the PPAP elements. Both the customer and manufacturer sign the elements package to ensure compliance. Design Records The design records include a copy of the final drawing outlining features, like the specifications, print notes, and standard tolerance notes. The customer usually sends the design records with the purchase order (PO). Authorized Engineering Change Documents Also known as an Engineering Change Notice, this document details a change. Specific authorized engineering change documents may not always be necessary, as the PO sometimes covers them. Customer Engineering Approval Allows the engineering trial to be performed at a customer plant with production parts. Third-party services are also available to audit factories prior to production. Design Failure Mode and Effects Analysis (DFMEA) It is reviewing components to identify potential weaknesses or failure modes. The DFMEA must be reviewed and approved by both the customer and the supplier. Process Flowchart This chart illustrates the sequence of the process. Process FMEA The PFMEA follows the process flowchart to identify what could go wrong when creating or assembling the components. Like with the DFMEA, the PFMEA must be signed off on by both parties. Control Plan The Control Plan outlines how potential issues are checked along the process, including the incoming quality, assembly process, or final inspections. Measurement System Analysis (MSA) The MSA typically contains the ANOVA gage repeatability and reproducibility (R&R) measurement system analysis technique to confirm that gauges used to measure critical or high impact characteristics are calibrated. Dimensional Results A documented list showing product characteristics, specifications, and measurement results – generally noted as “OK” or “Not OK.” Records of Material and Performance Tests – Design Verification Plan and Report (DVP&R) This report includes a summary of every test that was performed on the part being reported on. Initial Process Studies Provides all Statistical Process Control charts to show the stability of critical characteristics. Qualified Laboratory Documentation Each PPAP package requires a copy of all laboratory certifications from the labs that performed the tests. Appearance Approval Report (AAR) This report is a copy of the Appearance Approval Inspection (AAI) signed off on by the customer. Sample Production Parts This element provides a picture of the sample and where it was stored – either with the customer or the supplier. Master Sample The master sample is one that has been signed off by both the customer and the supplier. Checking Aids If there are special tools required for checking parts, this section of the PPAP package provides a picture of the tool and its calibration records. Customer Specific Requirements Best practices suggest that the supplier talks with the customer before quoting a job to learn what specific requirements they have on the PPAP. Part Submission Warrant (PSW) In the final form of the package, the PSW summarizes the entire PPAP package. Any deviations are noted on the warrant. When is PPAP Needed? Any significant modification or new component requires a PPAP approval process. The manufacturer is responsible for submitting the paperwork to ensure proper procedure. Generally, a customer or manufacturer should initiate PPAP paperwork after any of the following changes takes place: Using a new material to create a component The material supplier changes A new engineer is hired The manufacturer moves production to a new facility How Jonble Can Help Quality Assurance inspection before, during, and after production ensures that
Quality Control Begins With A Good Inspection Checklist
Almost every company in the world sources their products or parts for their products from China. Why? The lower costs, higher profit margins, and efficiencies gained by following the economic theory of comparative advantage are just a few reasons. However, when deciding to source from China, it is crucial to install rigorous product inspections. This quality control step is vital to ensure you satisfy customers and gain their loyalty. At Jonble, we understand the significance of each one of your products. It is not just an item to be boxed and shipped. It is the culmination of many years of hard work in developing, testing, and fabrication. Our experts will work with your team to create an inspection checklist that will guarantee high-quality control. With about 5 to 10 percent of purchases made in-stores and 15 to 40 percent of purchases made online returned, we understand that this adds up to millions and billions of dollars in loss. This blog will outline the steps to develop a high-quality inspection checklist to reduce the likelihood of products being returned for malfunction or other reasons. Create A WT Analysis Of Your Product The traditional Strength, Weaknesses, Opportunities, and Threats (SWOT) analysis is an integral part of your business planning, and it is equally essential in developing an inspection checklist. Inspection checklists should be developed with two purposes. It should check the quality of the item at the point in time within the supply chain. You want to consider both timing and product quality because this separates the process into stages to help identify weak areas that could be strengthened individually. Examine your supply chain and identify areas of weaknesses and threats. Is it sourcing raw materials or parts? Is it while assembling your product? Is it the final product before it is shipped? Is it the product after it is shipped? At every stage you identify, we can develop an inspection checklist to ensure quality control. Consider your product and the potential weaknesses and threats that should be examined during a quality inspection check? Is the material not suitable? Is the color not the correct shade? Can the product survive the long journey to your customer’s home? The inspection checklist will outline the quality and standards you expect of your product and ensure the customer’s expectation is also met. How To Get Started With Your Checklist When creating your inspection checklist, you should understand it is the guiding principles you will be providing for your quality inspection service provider to ensure factory and manufacturing standards are meeting your expectations. You cannot be everywhere. To alleviate your concerns and allow you to focus on your business strategy, think of the checklist as the blueprint that allows inspectors to be your right hand in the manufacturing and factory sites. Depending upon your item, your inspection checklist may vary in length. Start by identifying the different ways your product should be tested based on its areas of weaknesses. Once you’ve listed out these areas, there are a few ways you can organize the list. Typically, the inspection checklist names the type of check that is occurring, provide a description of how to conduct the check, and an area for measuring if the check was successful or not. How To Organize Your Checklist No one product is alike, and, therefore, no inspection checklist is the same. However, we’ve outlined below common types of inspection to include in your checklist. Visual Inspection – This type of inspection requires the inspector to look for visual anomalies. If your product is large, it could be walking around the product. It could be examining the color quality, looking for missing parts, if there are scratches, dents, or other marks. Physical Inspection – This type of inspection goes hand in hand with the visual inspection. It is important to check that the product matches the physical requirements such as dimensions and weight. Functional Testing – This type of inspection is vital to ensure your product does what it is supposed to do when it gets to your customer. The inspector should use the product and manipulate it to see if it holds up to stress. Barcode Verification – This type of inspection checks the barcode data matches with what is in your system and is easy to scan and verify. Drop Tests – This type of inspection helps to check that the product won’t break after a day or two of arriving at the customer’s or during the shipping process. The inspector should drop the product in the box and check if there is any damage to the box or the product. Special Tests – Every product will be different. A special inspection test is one that you develop based on your specific product. For example, if your product requires assembling parts together, then you should have the inspector also assemble the product to check it fits together well. How long does it take to assemble it? Does it match with any marketing language used on the packaging? These are the most common types of inspection checks that you’ll want to organize first on your checklist. Since your product may require additional types of inspection to meet regulatory or customer satisfaction, don’t let this list limit you. Questions Your Checklist Should Answer Once you’ve developed your inspection checklist, review it to ensure it meets your needs. When are checking it, consider if your inspection checklist answers these questions: Will the check test if my product looks like it should? Will the check test if my product does what it should? Will the check test if my product can survive the shipping process? Will the check test if my product matches the specifications I market to my customers? Will the check ensure the product my customers receive is the product they wanted? Does the checklist include detailed instructions on how to conduct each inspection test? Does the checklist provide all the information an inspector will need in order to complete the
What Are the Three Types of Conformity Assessments?
If you want to import or source goods from China as a foreign buyer, it’s essential to understand the significance of conformity assessments. The below guide provides critical information about the three different conformity assessments, allowing you to determine which one is best for your business needs. The Importance of Conformity Assessments Different countries have different standards in terms of safety and efficacy for various products and services. As an international business operating across borders, it’s up to you to know which standards are applicable in your region — and to ensure that any goods or services you import are in line with local regulations. Failing to meet standards can result in fines or lawsuits. A conformity assessment refers to the processes used to prove that a service or product meets these set standards. When applied to a product, a conformity assessment might involve testing that item to ensure it meets predefined performance standards and quality management, accreditation, and inspection criteria. Take a critical product like PPE (personal protective equipment), for example. These goods, like gowns and masks, help to prevent the spread of disease. Due to the COVID-19 crisis, healthcare providers globally have increased their demand for PPE. In some instances, this has resulted in dangerous shortages, leaving both workers and patients at risk. Countries unable to manufacture sufficient amounts of PPE themselves have had to import these goods. Of course, they want to ensure that the PPE they equip their healthcare workers with is up to safety and performance standards. Conformity assessments ensure this is the case. However, not all conformity assessments are equal. The Three Types of Conformity Assessments There are three types of conformity assessments, and they are viewed differently in terms of trustworthiness. Depending on the product or service being marketed, the relevant regulatory body may not accept all conformity assessment forms. For example, the International Electrotechnical Commission manages conformity assessments for electrotechnical products. Knowing which type of conformity assessment is relevant to your industry and understanding how that industry is regulated is critical. Here is the necessary information on conformity assessments to get you started. First-Party Conformity Assessment or Self-Declaration A first-party conformity assessment (CA) is also known as a self-declaration. In this case, the supplier or manufacturer declares that the product they’ve created adheres to the given specifications or standards required. The supplier or manufacturer will deliver a so-called SDoC (a supplier’s declaration of conformity) towards this end. This type of conformity assessment is understandably considered the least reliable and trustworthy. After all, it’s merely taking the manufacturer’s word for it. It all depends on the credibility of the supplier. There is no third-party proof or assessment. This type of conformity assessment is thus most common for products that are deemed low risk. An SDoC should be used only if the market allows it and is only recommended if the risks associated with non-compliance are low — and if there are options for swift recourse in the event of non-compliance. An SDoC is essentially just a label that provides commercial partners with a confident assurance that the minimum standard has been met. It won’t be relevant for products with life-altering effects, like medical devices, for instance. In these cases, local governments and regulatory bodies have more stringent requirements in place to assure quality. One example of an SDoC is the European CE mark. The CE mark is applied to specific products, confirming that they meet the European Union’s health, safety, and environmental regulations. It’s essentially one small piece of information telling you that the product meets the many different requirements outlined in the various EU directives. While it’s the least trustworthy of all conformity assessments, a first-party conformity assessment is also the cheapest. It doesn’t require independent verification from a third party. Many businesses will still opt to utilize a more stringent type of conformity assessment because it guarantees their products’ safety and efficacy and protects their business interests. Second-Party Conformity Assessment A second-party conformity assessment is considered a step above a first-party evaluation in terms of trustworthiness. In this case, a person or organization with no direct interest in confirming the product’s performance conducts the conformity assessment. A second-party conformity assessment is typically useful for large, significant, or demanding customers, such as a large-scale buyer, major manufacturer, or government entity. Such bodies will put the systems and operations needed to conduct conformity assessments for the products or services they purchase. This ensures maximum efficiency and convenience while also giving the body some oversight of the processes and results. They may even establish their own test facilities and write particular assessment guidelines, overseeing the process from start to finish to verify the quality of any goods or products they have bought. The main goal of such a second-party conformity assessment is to obtain an assurance that the supplier has indeed carried out their first-person conformity assessment in line with the client’s specifications. It’s like double-checking the self-declaration assessment. While this might seem like an added burden on the buyer, it’s actually in their best interests. For example, say an automobile manufacturer buys their engines in China. They want to make sure those engines are manufactured in line with safety regulations. Otherwise, if there is some safety issue related to the engines, the company’s reputation might be tarnished. This could result in a loss of market share and a decrease in profits. To avoid this nightmare scenario, the manufacturer may go ahead and request their engine supplier to perform a first-party conformity assessment. However, suppose the purchaser wants to be sure that the products they are receiving are up to par. In that case, they may then subject the engines to their additional second-party conformity assessment. Third-Party Conformity Assessment The final type of conformity assessment you need to know about is the third-party conformity assessment. This brings the highest level of trustworthiness with it. This is also referred to only as a “certification.” Third-party conformity provides the highest level of trustworthiness and the
How to Choose the Best AQL Level
Every product requires an inspection before you can release it, so when manufacturers mass-produce, they need to find a way to speed up the inspection process. One way to do this is Acceptance Quality Limit (AQL), a standard sampling method to determine the quality of a batch of products. However, not all regions and products have the same requirements for quality, so you will need to choose between various AQL levels to test your product. This test will limit the number of defective units in each released batch. What is AQL? AQL is shorthand for Acceptance Quality Limit, meaning the worst tolerable quality level according to ISO 2859-1:1999. The limit represents the most defective units a sample size can have before rejection of the entire produced batch. Its purpose is to help the buyer decide whether they should accept or reject a specific order of manufactured products. These are international standards to ensure product quality in any item being inspected, but the AQLs can vary between products. Products can have minor, major, and critical defects that would determine the percentage of products in a batch with that particular issue without needing to discard the entire thing. Also, inspections can be costly depending on the sample size, so figuring out the best risk to cost ratio is imperative to select the number of products to be tested and the AQL ratings for each defect. An AQL is necessary for your production. It ensures you release high-quality products that meet your customers’ needs without causing them harm. A suitable AQL will help your business in the long-run, despite a higher initial cost. Minor, Major, and Critical Defects Every form of production has three categories of defects: minor, major, and critical. These categories have different ratings that state the maximum percentage of products that can be defective. As the defects become more vital to the product’s usability, the limit decreases. A minor defect is a small deviation from the specifications. This defect does not affect the product’s performance and is unlikely to deter the customer from purchasing it. These are rated at 4.0%, meaning that up to 4.0% of the products can have that defect in a given batch without being rejected. An example would be a missing decorative stud. While not ideal, it has minimal impact on the product. Major defects include those that may not be accepted by the consumer, though they do not greatly impact the functionality. These defects reduce the value of the product but do not make it unacceptable to use. They usually have a rating of 2.5%. One example of a major defect would be a visible dent in a car door. Consumers would be less likely to buy the product, but it does not impact performance. The most stringent category is critical defects. A critical defect is unacceptable and dangerous to use. It greatly deviates from the specifications and industry standards, so that consumers should not be able to purchase it. These defects are usually rated at 0% because they should never be sold. An example of a critical defect is a microwave that operates with an open door. This issue could be extremely dangerous, so it should not pass an inspection. Overall, every mass-produced batch will have at least one defective unit. However, not all defects are created equal. By setting different AQL levels for each issue, you can sift out the dangerous products from the imperfect ones to inspect your production line. AQL Tables AQL tables are charts that help you determine the number of samples needed for inspection, and the number of allowable defective products based on the AQL. ISO 2859 includes these tables, and they have equivalents in all global standardization organizations. After choosing an AQL, the chart helps the buyer and manufacturer agree on inspection standards. You can use an online AQL calculator to find a suitable sample size and number of allowable defective units without tables. However, understanding the charts will help you determine if your product needs a larger or smaller sample size or AQL based on some of the below factors that a calculator cannot quantify. AQL Table Inspection Levels Three different inspection levels define the quantity that quality control will pick from for checking: Inspection Level I: the smallest sample size, designed for general inspections Inspection Level II: mid-sized sample, most commonly chosen because of its balanced risk to cost ratio Inspection Level III: large sample size, best for products with rigorous specifications, provides the most representative result of the quality, chosen the least because of its high cost and potential loss Factors that Determine Your AQL Limit Determining the severity of each defect depends on several factors, including the audience, the purpose, and consumer preferences. Audience Depending on the scope of your product, you may have to change your AQL based on the market. Different countries and cities have various tolerance standards for critical, major, and minor defects. The values mentioned above of 0%, 2.5%, and 4.0% are North America and Europe’s standards. Understanding the quality expectations of your target audience and the regional standards will help you determine the severity of your AQL. Budget Inspections aren’t free, and larger sample sizes cost more to inspect. A larger sample size has a higher time, labor, and monetary cost to perform an inspection, but it will provide the most accurate result. If you are testing a riskier product, like a prescription drug, a larger sample size may be worth the extra costs to avoid causing harm to consumers. Purpose Not all products require surgical precision to be sold. For example, if a batch of candleholders has some products with misshapen dishes, it’s not as big of an issue as an airplane with a deformed wing. Items designed for transportation, ingestion, pharmaceuticals, electronics, and appliances have more rigorous inspection standards than something like clothes or decorations. Critical issues with those products could kill someone, so they need much lower AQL ratings than other items. Also, riskier products
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
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
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
What Is First Article Inspection: The Basics
If you’re thinking about expanding your market or manufacturing to a foreign market like China, you’re going to need to be quite involved in the manufacturing process overseas. Not only will you need to learn more about how things like patent law and intellectual property law work in China, but you’ll need to make trips to the production plant to ensure that everything is going according to plan. During such trips, it would be wise to conduct a first article inspection in order to ensure that the parts for your product align with the designated design plans before mass production begins. But what exactly is a first article inspection? How does it work, and is it really necessary? Let’s take a look. What is First Article Inspection? A first article inspection (often abbreviated as FAI) is the process of authentication for a manufacturing process. A report for a first article inspection will utilize the different dimensional properties of a specific part in production and compare it to the initial design specifications. There is a wide range of elements that need to be checked during a first article inspection and can include weight, density, color, finish, hole position, etc. There are a number of FAI inputs that inspectors will use. Mainly, a 2D drawing or 3D model will be created, and material or process specifications will also be documented. Once the inspection is complete, you’ll need to create a first article inspection report (also known as FAIR) which will include a part drawing, verified measurements of the part’s elements, and possibly some extra checklist items that might be needed by the customer. When is a First Article Inspection Conducted? Typically, a first article inspection is called for after a purchase order contract is finalized between a producer and buyer. Because a first article inspection is a production process that verifies the quality and accuracy of a product or part, it should be conducted after all designs are complete. Once a design is finalized and the right production modes have been set on, a first article inspection can be performed during the initial production run. Just as well, a first article inspection should be conducted each and every time there is a design change that will affect the fit or function of the product itself. In fact, a first article inspection should be reported if there is a material or source change, after two years since the last FAI report, and whenever there is a change in process or manufacturing location. If you’re able to travel overseas to your supplier or manufacturer’s plant, it would be wise to conduct a first article inspection when you’re physically there. Why are First Article Inspections Performed? Typically, first article inspections are often associated with particular industries like aerospace, automotive, electronics, medical device, etc. In such industries, the precision of the production parts is vital. Car parts or components for a plane engine need to be heavily monitored during production to make sure that each and every part aligns with design plans, complies with safety regulations, and is able to perform the function it was designed to perform. The Benefits of First Article Inspections for Mass Production Without a first article inspection, manufacturers and businesses would waste a significant amount of resources by continuing with initial production procedures with faulty or inaccurate parts. To put it simply, a first article inspection is 100% necessary for businesses in these industries. Just as well, industries like aerospace and medical device tend to have their own specific procedure regulations that have to be followed, which usually involve some form of a first article inspection. An in-depth inspect will ensure that everything is okay with your equipment, settings, techniques, and materials before you move along with production and finish the purchase order. Not only are you saving money by implementing an inspection, but you’re also reducing waste at the factory and speeding along production by finding errors and remedying them quickly. When Should a First Article Inspection be Implemented? It may seem wise to conduct an inspection before production begins, but this kind of defeats the purpose of the FAI in the first place. The purpose of this type of inspection is to identify errors or quality issues that occur between the design phase and the production phase. You won’t be able to identify these issues easily without a trial production run to see how things are actually moving. You should also consider your industry and the type of products you create before considering a first article inspection. Generally, most industries do not require this type of inspection, such as low-cost consumer goods, promotional products, etc. Rather, you should implement this inspection if you are part of an industry in which part dimensions are critical to the function or the product or you manufacture parts needed for planes, cars, and medical devices to function. How Can I Implement a First Article Inspection? Typically, a first article inspection is conducted by a trained technician or a quality control employee at the factory. However, third-party quality control inspection companies tend to be the most ideal. Jonble Company is one such product inspection and quality control platform. Based in China, Jonble Company focuses specifically on providing product inspection services to foreign businesses that are working with China-based manufacturers and suppliers. From pre-shipment inspections to first article inspections to container loading inspections, the talented QC professionals at Jonble Company can help you get some peace of mind after expanding your business to the Chinese market. If you’re in need of a full factory audit (which is recommended before getting into an agreement or contract with a supplier), Jonble Company also provides factory audit and full facility inspection services as well. There’s no need to take on the task of inspections and quality control alone.