As the process seems not to be clear for all our clients, we
have decided to shed light on this important subject.
How do we select the cartons to inspect ?
The rule we apply
at INHOUSE INCORPORATION is to randomly
select the square root of cartons (total number of cartons))and then to
randomly select the chosen sampling size. First the cartons are selected
randomly, and then the samples are selected randomly from within these cartons
.
We strictly advise
to select at least a Level II inspection which we believe is the very minimum
sampling size to select for a reliable inspection of your products!
Some clients have
their own rules (less or more strict) but we believe that ISO 2859-1:1989 is a
safe choice, especially when choosing the tightened AQL level (III) (or your
own tighter custom level as the only way to know if 100% of your products are
ok is to check all 100%).
How we identify the
inspected cartons ?
We used to put sticker on the cartons but
our standard practice is now to put a stamp on the selected cartons. Why?
Simply in order to more easily identify those cartons (cartons are usually
carried to the “inspection space” by the factory staff when selected by the
inspector) later on if needed. Putting stickers was too difficult to manage as
we open hundreds of cartons every week and putting tape made no sense since
normally, products and cartons are not repacked by the inspector after the
inspection.
When the
manufacturer inputs a carton number on the export cartons (usually asked by
clients in most cases and very recommended), we also input the carton numbers
on the final report (in part A: AQL inspection details)
The point of those two methods is simply to know which
cartons were inspected and see if the sampling was done on the right quantity;
Of course, it does not mean that all products in those cartons were checked.
Also note that when repacking, it is of course very likely that inspected
products will be mixed between the different opened cartons, inevitably
jostling the random repartition of defects and inspected products.
Why are inspected products and cartons not repacked by the inspector
after the inspection?
Because
repackaging and repacking takes time (from 1 to several hours) and the factory
does not always provide the manpower for this. This is why it is commonly
accepted that this is the factory’s responsibility.
Because the
factory’s QC people shall normally recheck all defective products to better
understand the issues (in best case scenario).
Because the
factory shall rework or reproduce the defective products (we find problems on
mass production on 99.5% of cases) or in case of a failed inspection, it is
likely that the client will ask the manufacturer to sort out the defective
products and rework or reproduce them, so there is little point in repacking.
Packing needs special technique, while
inspector are not well trained in this.
Can we seal the inspected cartons?
We can of course
adapt to clients requesting custom-made solutions for their business but
sealing the inspected cartons only makes sense for small orders and passed
inspections.
We can perform
most of client’s specific request but this is not a typical practice. This
doesn’t make much sense unless you really do not trust your factory; Even if
this is the case, if factory is really dishonest, they could easily replace
non-inspected cartons with lower quality products in order to sabotage the
inspector.
In terms of
sealing cartons, what makes sense, but is again not a normal practice, is to
seal inspected cartons when inspection is PASSED. But because generally not all
products from a carton are inspected, we should only seal the cartons that are
newly packed with only inspected and passed products and wait for final
repacking by the factory!
Products selected for inspection:
It is standard
practice to put defective products aside so the factory can rework them or
replace them.
Note that some
clients have special instructions about defective products, for example: to
seal them so that client can request factory to send it if needed, to
automatically send to client the major defects when it concerns more than 1% or
X% of the sampling size, to send the worst defects to client when inspection is
failed, etc.
Non defective
products are usually repackaged by factory workers when inspector finishes the
inspection or even sometimes when the inspector has just checked the product.
However, often the factory will decide to repackage products and cartons later with
the appropriate team.
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