Case Studies

No factory in the world produces perfect products all the time. It does not happen in heavy industry such as the aerospace industry or light industry such as the consumer products industry.

In the manufacturing industry, product defects are unavoidable. They can come in forms, sizes, and severities. High defect rate becomes an issue that can impact your business as an importer and your bottom line.

How to manage the defective products?

Handling defects begins with setting expectations during the sourcing process and goes on throughout production until the supplier ships out the finished products.

Detect Defective Goods with Production Inspection

One of the best ways to manage defective goods is to catch quality issues early on. By identifying the problems before shipment, you can avoid problems due to poor product quality.

There are different stages of the production inspection that you can examine the state of the order. You can either inspect the products on your own or hire a third-party inspection company. The latter option is better as it is more efficient and cost-effective in the long run.

• Initial Product Inspection

   

  

Inspecting raw materials and components before production starts can expose costly quality issues. You can inspect the incoming raw materials in the warehouses before the factory starts the production. It is always better to catch any quality issues related to raw materials and components early on.

• DUPRO inspection

A during production (DUPRO) inspection helps you detect the issues while production is underway. To identify any problems occurring during a specific process, the inspector can pull samples of the products during different production stages.

This type of inspection is beneficial when dealing with the shipment of large quantities of products with ongoing production, products with several production stages, and products susceptible to defects that cannot be fixed later.

• Final Random Inspection

Final Inspection happens near the end of production, usually when 80% of an order of goods is done and packaged.

This type of inspection typically involves checking a random sample of goods and looking for quality defects, non-conformities, and other issues.

Set Clear Expectation When Selecting Supplier

• Production Requirements

Before choosing a supplier, you should have some idea about your product requirements. You should clearly convey your product requirements to your supplier, as then, you will less likely receive defective or unsellable goods.

• Product Defect Tolerances

Create a detailed QC checklist to classify defects early on. It will show a breakdown of possible product defects and how they should be classified.

Once the different types of defects are appropriately sorted in the checklist with the quantify tolerance for each. Quality control practices usually depend on acceptance sampling to determine whether to accept or reject a shipment.

Conclusion

You can try as hard as you can, but defects are a part of the production process. Whether it is a minor defect or a critical one to consumer’s safety, managing the issues with your supplier is essential. If you arrange production inspections to handle defective products, you can save money, time, and brand reputation.

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