Random inspection for quality is a widely used QC service for consumer products purchased in Asia. It is the most popular method used to authorize shipment and trigger payment. However, there are certain situations where a 100% quality inspection may be necessary.
This article will explore the differences between random inspection and 100% quality inspection, and provide insight into when each method is appropriate. It will also discuss the costs associated with each method and whether or not 100% quality inspection should be finished in the supplier’s factory. Additionally, the article will examine the practice between full inspection and random inspection for quality in China.
Key Takeaways
- Random inspection is the most popular QC service for consumer products purchased in Asia.
- The article explores the differences between random inspection and 100% quality inspection and discusses when each method is appropriate.
- The article also examines the costs associated with each method and whether or not 100% quality inspection should be finished in the supplier’s factory.
When Do You Need a Random Inspection?
As part of their quality control plan, importers should decide when to conduct random inspections for quality. In most cases, sellers follow ISO 2859-1 (or ANSI / ASQ Z1.4) to set the inspection level and the AQL limit. Random quality checks are used by most buyers to reduce the amount of work.
Types of Random Inspections for Quality During Different Stages:
Random inspections can be conducted during different stages of production to ensure quality. These stages include supplier selection, factory audit, sample test, pre-production inspection, during production inspection, pre-shipment inspection, and container loading inspection. The percentage of finished production checked during shipment varies, with 5% for suppliers selection, 30% for pre-production inspection, and 80% for during production inspection.
Who Needs a Random Inspection Check?
Importers who work with multiple suppliers and whose quality standards indicate 2-3% of secondary products may need to conduct random inspections. However, not all products need to be checked. If a manufacturer has great systems and processes, and they have a history of complying with the importer’s quality standard, there is usually no reason to send a quality company to their facility. Similarly, if the entire batch can be returned and reworked quickly, there is no need to spend resources on random inspections for quality.
What is Checked During Random Inspection for Quality?
Three types of problems can lead to inspection failure and possible rejection of shipment by the buyer. The first type is conformity to specifications, where all relevant aspects of the product are controlled, including quantity, components, assembly, aesthetics, function, dimensions, labeling, packaging, etc. The buyer should prepare a document listing all specifications for the product to be inspected, which will serve as a checklist for the inspector. If no such information is provided, the inspector collects the information for the buyer’s review.
The second type is the number of cosmetic defects, where the inspector randomly selects a predetermined number of products according to the sampling plan. The inspector inspects and counts the number of defects one by one and compares them with the AQL limits.
The third type is on-site testing, where specific tests are included in the inspector’s work depending on the product type. For example, product drop test with three samples from a concrete floor of 80cm height (test fails if at least one sample breaks or no longer works).
What is the Random Inspection Limit?
Importers often put a lot of pressure on suppliers, who may face difficult price renegotiations (or even cancellation of orders) if the product has serious quality problems. QC inspectors are seen as the police and can be bribed if monitoring is not adequate. There is no 100% guarantee as random inspections are conducted on a randomly selected sample, not on the entire quantity. Even if so-called “normal” or “tightened” levels are followed, there is always a small chance that the findings will not apply to the entire shipment. Likewise, a dishonest factory can short-order or switch products before shipping (unless the shipment is also monitored).
It may be too late if the buyer sends inspectors after production is complete. Either because the defective product must be reproduced or because the rework time is too long. Therefore, it is recommended to conduct random inspections for quality during production. This way, problems will be detected early, and some suppliers see them as help rather than supervision.
When Do You Need a 100% Quality Inspection?
Importers may opt for a 100% quality inspection when faced with high return defective products fees. In such cases, it is often worth investing more time and money to ensure that all defective products are identified and removed from the shipment. Additionally, when importers have strong suspicions that the supplier’s quality control is not up to par, a 100% quality inspection can help to identify and address any hidden quality issues.
Another reason why importers may choose to conduct a 100% quality inspection is to replace inferior products with quality ones. By identifying and removing any defective products, importers can ensure that the final shipment meets their quality standards. Overall, a 100% quality inspection can provide importers with the confidence and assurance they need to ensure the quality of their products.
Is it More Expensive to Do Random Inspection vs 100% Quality Inspection?
The cost of inspection is an important consideration for importers who want to ensure that their products meet quality standards. While most people may assume that random inspection is more expensive than 100% quality inspection, this is not always the case. In some situations, the cost of full load inspection can be very similar.
To illustrate this point, let’s consider an example where a product has 1% defects that are easy to examine. The unit price of the product is $5, and the fixed installation cost is approximately $100. An inspector can check 50 items within one hour, and the operator is charged RMB100 per hour for all time the product is inspected. The cost of sending a professional QC to the factory is $299 per person per day.
To make a fair comparison, importers will still need to pay for the defective goods after a random inspection. The following table compares the cost of random inspection versus 100% quality inspection:
| Inspection Type | Inspection Cost |
|---|---|
| Random Inspection | $215.80 |
| 100% Quality Inspection | $250.00 |
As shown in the table, random inspection in this scenario is actually less expensive than 100% quality inspection. Importers can save money by conducting random inspections when the defects are easy to examine and the cost of inspection is low. However, it is important to note that this cost comparison may vary depending on the product, defect rate, and inspection costs.
Should 100% Quality Inspection be Completed in the Supplier’s Factory?
For small quantity and simple products, completing 100% quality inspection in the factory where the goods are manufactured can be a viable option. However, if the work required more than five working days, the cost would increase significantly, making it an unrealistic option.
Supplyia suggests delivering a batch of products to their warehouse to do 100% inspection by trained operators, and repacked immediately. This approach is more efficient and much cheaper than hiring people to do it in the factory. One of the great advantages of this approach is speed and simplicity.
Practice Between Full Inspection and Random Inspection for Quality in China
To ensure quality control in China, some importers have adopted a new approach with the help of their clients. They start with piece-by-piece inspection in China, which is paid for by the manufacturer. This allows them to identify the most common defects and provide advice to the manufacturer to reduce them. If the proportion of defectives falls below a certain target, they switch to random inspections, which are paid for by the importer. However, if the proportion of defectives increases again, they switch back to full inspection or piece-by-piece inspection, which is paid for by the manufacturer.
This practice not only ensures that the factory solves the real issues, but it also reduces costs for the importer in the mid-to-long run. If importers need random inspection for quality in China, they can contact the relevant parties to implement this approach. By using this method, importers can be confident that they are receiving high-quality products from their Chinese manufacturers.