4 Common

Misconceptions
About Product Inspection Services
 4 Common Misconceptions About Product Inspection Services

Introduction
Product Inspection Services are the verification of product quality to pre-identified quality
specifications before, during, and after the production process. Prior to the manufacturing
process, raw materials can be inspected to identify if the materials themselves meet
specifications. During the manufacturing process, products are inspected at the factory to
verify that quality requirements and specifications are being met. After production, goods
can be inspected prior to loading and unloading to verify that the approved final product
is shipped and received according to the buyer’s requirements. Inspections throughout
the various stages of production can help both buyer and manufacturers monitor that
quality requirements for the product are being met and support on-time delivery of quality
products.

With decreasing product lifecycle and time-to-market, the challenge to deliver quality
products on-time increases. If a product does not meet the appropriate quality
specifications for the marketplace – either after or late in the production stage – the
result can be loss of product and revenues, delayed shipment or wasted materials, and the
potential risk of a product recall. Therefore, delivering quality is the core mission of Product
Inspection Services.

In this white paper, we’ll discuss four common misconceptions about Product Inspection
Services in detail in order to provide a clear depiction of industry truths, best practices, and
key insights.

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 4 Common Misconceptions About Product Inspection Services

1. Inspections guarantee that no defective products are shipped to the customer.

Product inspections aim to ensure that all products arrive to customers exactly as
specified in the orders. From Pre-Production to During Production (DUPRO) to
Pre-Shipment and, finally, to Loading Inspections, quality, on-site inspections are
conducted that follow AQL standards. ‘AQL’ stands for ‘Acceptance Quality Limit’ and
represents the quality level that is the worst tolerable in product inspections. There will
be defective products in virtually every production batch, and the use of an AQL-based
inspection provides the data necessary for a buyer to determine whether to accept or
reject the shipment, which is referenced during the Pre-Shipment inspection.

So, what makes a product defective? If a consumable, commercially produced and

distributed good is unfit for its intended use, dangerous or harmful for normal use,
does not carry adequate instructions for its use, or is inherently dangerous due to
defective design, assembly, or manufacture, it is defined as being defective. There may
be a design defect, resulting from the product having been poorly designed or tested, so
that the design itself yields a product that cannot perform its desired function. Even if
the design is correct, the product may have a manufacturing defect if it was incorrectly
manufactured – for example, if the wrong materials are used. A product may also be
considered legally defective if it lacks appropriate instructions for its use, or appropriate
warnings of dangers accompanying normal use or misuse of the item. Defects can be
categorized as: Critical, Major, or Minor.

So, although quality product inspections serve the purpose of identifying defective
products so that they’re not shipped to the customers, it is possible for some to fall
through the cracks. Since only a sample of the order is inspected for defects in an AQL
procedure, there could be an individual product that was overseen – and is actually
defective – that ends up being shipped.

There could also be issues with the order or the shipment that the inspection portion of
the process has no control over. Product inspections follow the orders provided and then
hand off the inspected products to Shipment after the Loading Inspection is completed.
These pieces are separate from the actual inspection, so issues could very well occur
either before or after it that create problems, meaning what is shipped is not what was
intended and the customer ends up dissatisfied.

2. Inspections make products quality.

After products pass inspection, it’s expected that quality items will be delivered to the
customers. A product passes inspection when it follows your established AQL standards. This
means there may be some defects found, but few enough that it is within the acceptable level.

It is important to note that inspections don’t insert quality into the products being
inspected. Let’s firstly define Quality. Every product or service has a requirement
– a description of what the customer needs. When a particular product meets that
requirement, it has achieved quality, provided that the requirement accurately describes
what the customer actually needs. In short, the customer is the one who truly defines
Quality in the manufacturing process.

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 4 Common Misconceptions About Product Inspection Services

Manufacturers must detect and investigate product quality deviations in order to

determine whether or not a product meets the specified requirements, which also helps to
guarantee that the customer will be satisfied. But, if the product has a quality issue built
in, the inspection isn’t capable of fixing this. You simply can’t inspect quality into a product
if it doesn’t initially exist. So, if a customer receives an item that is not high quality, this
doesn’t necessarily mean that the inspection failed in fulfilling its requirements.

3. Inspections fix product issues.

Remember that inspections detect issues; they don’t fix issues. If an inspector identifies
a defect, he or she needs to notify the factory management so that they can determine
the root of the issue. If the problem arose during the manufacturing process, management
needs to then fine-tune its practices in order to remedy existing weak points. It’s not an
inspector’s job to fix the problem; this responsibility lies in other hands.

Good Manufacturing Practices (GMP) that factory managers should uphold include:

• Clearly defined manufacturing processes 

GMP covers all aspects of production from the starting materials, premises and
equipment to the training and personal hygiene of staff. Detailed, written procedures
are essential for each process that could affect the quality of the finished product.
There must be systems to provide documented proof that correct procedures are
consistently followed at each step in the manufacturing process – every time a product
is made.  

• Training to ensure that operators are properly performing 

GMP compliance is widely accepted as the best way to conduct business, putting
product quality first. Courses combine a convenient format with an effective,
interactive learning experience to maximize and customize your professional
development. In order to ensure that operators are performing their tasks optimally,
proper training is required. 

• A process to handle customer complaints 

It’s important to have a set process in place for handling customer complaints in an
orderly and composed fashion. This type of process can act as a “warning system”
that there may be an issue with a product in terms of design, materials, etc. This will
help you remain aware of any issues at hand and effectively communicate them to
customers who’d be affected by the mistakes. 

• Maintaining accurate and complete records of manufacture

This is essential for ensuring traceability in the case of any issues, recalls, or necessary
reworking of products. Your records should always be detailed and accurate. In any
industry, and especially in manufacturing, it’s crucial to cross your t’s and dot your i’s.
So, make sure to maintain your records.

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 4 Common Misconceptions About Product Inspection Services

• Detecting and investigating product quality deviations 

This is only possible if manufacturers monitor their production and conduct inspections
that document the findings. Then, they review this in order to identify any deviations.
When product quality is thoroughly investigated, it’s clear whether or not a product
meets its requirements. This also helps to guarantee that the customer will be satisfied. 

By following these best practices, factories will be able to diminish production issues.
Although inspections aren’t capable of fixing product issues, they should still be dealt with
in the correct manner.

4. After inspections, products are shipped without defects.

Products that pass inspection are seemingly defect-free. But, as discussed in #1, some
defects may still exist in the shipment. Products may be perfect right after inspection,
but things could potentially go awry during the shipment process, due to a change in
environment or conditions. For example, if you’re shipping something that is made of
wood, it could split during the shipment if moisture levels change. Increased moisture
could also create the growth of mold on certain products being shipped. Even though
products may pass inspection with no issues, it is possible for defects to develop during
transportation.

Items should be shipped with the ultimate care, but unfortunately this doesn’t always
happen. The supply chain is lengthy, with numerous touch points, so mistakes can happen
at times. This just drives manufacturers and inspectors to work harder in order to ensure
quality as best they can.

Key Takeaway
Now that we’ve offered a comprehensive and insightful glimpse into the manufacturing
industry – specifically the inspection process – you will have a better understanding of
what exactly inspections are meant to accomplish, the issues that could arise and how
to deal with them, how to define and identify defects, and the importance of upholding
quality throughout the supply chain. Information is easily misconstrued – especially in
an oftentimes complicated and even confusing industry such as this one – but these key
explanations of the most common misconceptions will clear up uncertainties and effectively
inform interested parties.

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WWW.INSIGHT-QUALITY.COM

Insight Quality Services is an independent third-party quality control

services company providing on-site Product Inspections, Factory
Audits, and Consulting Services throughout North America & Asia.
We exist to provide you unbiased information to ensure your products
meet your specifications and quality standards before they leave the factory.