Keywords: quality control, product assurance, check sample
Companies must inspect their products before shipping them outside the production area. Companies that use raw materials from foreign suppliers can also contact inspection agencies within such locations to determine the quality of the material. However, manufacturing companies still have an opinion on the inspection process. A quality inspector will perform the task based on the company's demand. There are specific options to consider and questions you may want to ask yourself.
Product testing is not limited to any particular environment. The most important is identifying the good and rejected products. Inspectors will take out a check sample among the whole batch and run it through an acceptance check. The entire product or set is considered unacceptable if any defect is detected.
This is mainly carried out post-production before shipment. Most suppliers are familiar with this method, so they prepare ahead of the inspection. It is also easy to execute and can be done quickly with several suppliers in different locations.
The negative side of this process is the need for a concrete agreement between a supplier and a quality inspector. Suppliers may refuse to rework a product, especially when it requires excess resources and time. Sometimes, suppliers also bribe inspectors to overlook little errors. All these will be fine if you work with an integrity inspector with good skills in relating with others.
This option is time-consuming and best ideal for producing in low quantities. The defect rate from this method is also very low or zero. The problems are quickly identified and clear as quality inspectors communicate areas that need improvement to the manufacturers. However, this method is expensive. It is also more appropriate for items shipped to one geographical location.
Final inspection applies when buyers want to confirm the quality of the produced items. Suppliers barely interfere in this option but can create an inspection room, often in the form of a warehouse. All the goods can be tested, while some buyers may only check some parts of the whole product. The main benefit of this option is the elimination of travel expenses.
Factories can have their internal inspector, but they need to be trained in inspection and auditing. More so, internal inspectors may take a long time before getting familiar with quality control. However, most consumers prefer to avoid this approach, especially when they trust the company and have patronized it for some time. This means they are sure of getting quality products to a large extent.
The following questions will give you a better idea of the right option. It will also help to determine the intensity of the quality control inspection.
Quality management will start from the pre-production stage if this is the first time a supplier works on a product. It helps to identify any possible defect early, to reduce rework. The production team will also have to give feedback at every manufacturing stage. Thus, a quality inspector must check if things are still in order. Professional quality management will also involve a team that suggests countermeasures to identified issues or problems.
Buyers purchasing in small quantities mostly suspend guarantee at the final production stage. A company that produces high-quality and acceptable products will not need close monitoring. However, some companies still monitor production quality closely, especially when a lot is at stake. It is also employed when it is essential to show verification and authentication proof.
Before inspecting a product batch, the company will communicate the maximum defect percentage expected from an inspection. Typically, the defect tolerance should be between 1% and 3%. Companies that directly affect consumers' well-being, such as food and beverages, would not tolerate slight identification of the defect. Meanwhile, the fashion industry's defect tolerance will be higher, including checking for QC shoes. Thus, your product type will determine the level of the defect you can tolerate. If you need more clarification about the acceptable defect that works for your company, an experienced quality inspector can help.
Whatever option you decide to work with, a company should provide the inspector with a checklist during check samples. Also, an inspection checklist allows inspectors to check if the quality control process meets buyers' instructions. Below are the typical steps used in quality control and the role of a list in ensuring the process's effectiveness.
You may provide your team with reference materials or approved samples as a check sample for product testing. It would be best if you also created a checklist of new features that should have been included in the previous pieces. This may include product color, weight and dimensions, marking and labeling, and general appearance. Thus, you need to specify every information required in testing QC shoes alongside other manufactured products.
When inspectors use the random sampling approach, they implement the statistical strategy. You must create a checklist that identifies the number of samples examined within a particular batch. This will also help inspectors to achieve an accurate result, as some suppliers may cherry-pick some pieces above others. This happens when they want to prevent quality inspectors from finding out about a defect. Thus, they are confident a particular set of products will yield an acceptable result.
In random selection, the sample size should be at the top checklist. It will prevent quality inspectors from checking too many products, which may eventually lead to time wasting. It may also lead to money wastage, especially when the inspection requires excess resources. Also, if the quality inspector checks below the sample size, it will affect result accuracy. Defects may be detected less than the actual volume.
The work of a quality inspector extends to the packaging stage. This ensures end consumers get their products without any damage. It may seem easy to identify packaging defects, but some inspectors need to pay attention to them, especially when there is no checklist. The packaging checklist should include shipper weight, shipper dimensions, and artwork. Also, finished goods may be damaged during transportation and not necessarily at the manufacturing stage. This is why inspectors should get involved in the supply chain.
When quality inspectors work with a checklist, it is easier to give a detailed report on the errors. It also helps inspectors to report appropriately based on the product type. For instance, the possible report on an injection-moulded product is flash, and for wooden products would be warping. Also, a checklist will classify the severity of the defect. It could be a critical, major, or minor flaw. Defects under the minor category should also have a tolerance level. For instance, to what extent of minor defects would a cloth be unfit for winter? It would be best to consider your customers' expectations when creating a checklist, as it will help address possible future issues.
On-site product testing is mainly used for a wide variety of products. The quality control checklist will test products' safety and performance levels. It also applies when testing products with different components. A perfect example is an electronic kettle. The base must fit into the upper part of the kettle, the cable must be in good condition, and the lid should be well-covered. Thus, every aspect of the product will be tested to confirm its functionality.
If your quality inspector is not sound, it will affect the production output and market revenue. A quality inspector who pays no attention to crucial details may accept the wrong products. This will put both the customers and the business at risk.
It is also essential to hire a third-party inspector, especially when you want to achieve top-notch quality management. A third-party inspector will make sure to provide the necessary tools, which the supplier may need to provide. Some of these tools include callipers, barcode scanners, and tape measures. These tools are portable and easy to move around. However, professional inspectors will recommend heavy objects, like lightboxes or metal detectors, should be at the testing site. Thus, inspecting product quality is more successful when the needed materials are available.
A professional operation from the EU Global Inspection Company will provide you with every information you need before the inspection. The company's services cover 29 significant categories, including clothing and home textiles, consumer goods, electronics, footwear, and many other sectors. Sensitive categories like food and personal care will be handled specially and stored appropriately. Companies working with EU Global Inspection can choose from widely available expert third-party providers. If you still need to work with the EU Global Inspection Company, contact the customer service team to get on board.