From drawing to dock · step 9 of 10
Step 9: Inspection. Checked before it ships.
Every order is checked four times: the incoming material, the first article, the parts while the line runs, and the lot before it ships, to a sampling standard of AQL 2.5 to 4.0 set by the product and your requirements. Jack's own people do it, and third-party inspection companies such as Topwin when needed.
What happens in this step
The cheap place to catch a problem is before the container.
- Incoming material. Is the resin, steel or fabric that arrived the one on the quote?
- First article. The first parts measured against your drawing before volume is released.
- In-process. Parts pulled while the line runs, so drift is caught early.
- Pre-shipment. Count, pack and a sample of the lot against the approved sample.
Jack speaks Mandarin on the floor in Taiwan and China, and Vietnamese translators sit with his inspectors in Vietnam. The full service, including line watch on programs you already run elsewhere, is on line watch.
What you send us
The reference every lot is judged against.
- The approved sample and the drawing.
- The AQL you need, or the product and your customer's requirements so it can be set.
- Critical dimensions and any functional test.
- Packing and marking requirements.
What you get back
Findings you can act on.
- Inspection results for each check, in English.
- A problem held at origin, where fixing it is still cheap.
- A sample inspection report on request, so you can see the format first.
What it costs
Line watch is $350 a day, per inspector.
That rate covers one of Jack's inspectors on your line for a day. The number of days depends on the order and the checks you need. Holding part of the balance until the pre-shipment check is also the simplest way to keep leverage; see payment terms that protect a buyer.
Common mistakes at this stage
How bad lots get shipped.
- Inspecting only the finished lot, after the material and the process have already drifted.
- Using a day-rate inspector who leaves before the problem starts.
- Not having the signed sample at the factory for comparison.
- Paying the full balance before the pre-shipment check.
- Setting one AQL for every product instead of one that fits.
How the four checks work together
Each check catches what the last one cannot.
A final inspection alone tells you whether a finished lot is good. By then the material has been bought, the parts molded or sewn, and the goods packed. Finding a problem at that stage still saves you from shipping it, but fixing it is slow and expensive.
The earlier checks are there to stop a bad lot from being made at all. Incoming material catches the wrong resin, steel or fabric before it is used. The first article catches a process that does not match the drawing before volume starts. In-process checks catch drift while it is small. The pre-shipment check then confirms the count, the packing and the lot.
- The inspector works from the approved sample and the drawing, not from memory.
- Findings are written in English, with photos.
- A failed check holds the lot at origin until it is fixed and re-checked.
- The sampling level follows the AQL you set, from 2.5 to 4.0 depending on the product.
Line watch applies the same approach to a line you already run with another supplier. Jack's inspectors sit on that line, report what they see and flag drift early, without you having to move the program.
Inventor or business?
The same step, from where you stand.
Starting out. If this is your first product, you may not know what AQL to ask for. Tell Jack what the product does and who buys it, and the sampling level is set to fit.
Already selling. If you already have a quality standard, send it. Your AQL, your checklist and your approved sample become the inspector's reference, and the findings come back in the format you already use.
Questions
What people ask about this step.
What AQL do you use?
Between AQL 2.5 and 4.0, set by the product and your requirements.
How much does line watch cost?
Line watch is $350 a day, per inspector.
Who does the inspection?
Jack's own inspection team, and reputable third-party inspection companies such as Topwin when needed.
Can I see an inspection report?
A sample report is available on request. Reports from other customers' programs are not published.
Can you inspect a line I already run elsewhere?
Yes. That is line watch.
Related
Have something to make?
Send what you have. Jack reads it himself, and we’ll sign your NDA — or use ours — before you share details.