In order to effectively prepare for a product inspection, you must first begin with a thorough checklist. An inspection checklist is typically prepared by the buyer’s quality department or by a third-party quality control (QC) firm. The checklist should be completed before manufacturing starts and attached as an appendix to the purchase order and/or the contract. An inspector will utilize the checklist during the process as soon as finished products come off the assembly line so that they can catch issues early on.
Here are the 3 major categories that the checkpoints will fall under:
- Specifications
Specifications are anything that should be verified and then compared to pre-established requirements. Every sample that does not conform to the buyer’s requirements should be documented and reviewed by the buyer for disposition. For consumer goods, specifications usually cover:
- Material and components
- Assembly/workmanship
- Colors, finishing, and aspect
- Size, weight, and other measurements
- Labeling, logo, tags, stickers
- Packaging: retail packing, cartons, shipping marks
Specifications are listed by description, required result, and tolerance.
- Defects
Defects are defined as anything that can be noticed visually, generally at arm’s length. These checkpoints are applied to every sample selected by the inspector. Every imperfection is counted as 1 defect (the maximum is 1 defect per sample), and is categorized as either Critical, Major, or Minor. Then, the inspector compares the number of defects to the AQL limits.
- On-site Tests
These are anything that should be verified by using a specific method and/or device. On-site tests are generally performed using special inspection level 2 (S2), if they are destructive and/or may be time-consuming. If 1 sample breaks or stops functioning, the test is failed. Tests that are related to user safety, are not destructive, and are not very time-consuming are performed on all the samples that are checked for defects. If the test is failed on 2 samples, it generates 2 critical defects and the inspection is failed. Examples of on-site tests include a Drop Test and a Hi-pot Test.
If you define your requirements clearly and place them in the proper category, you will reduce confusion for your supplier and for the inspector. By understanding these 3 important facets of properly preparing, you will have a clearer picture of the manufacturing process and how much thoroughness and quality comes into play along the supply chain.
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