Quality FAQ

There are three primary stages of product inspections: first-article, in-process, and pre-shipment inspections.

First-article inspection is performed at the start of production to ensure the product meets required specifications before full manufacturing begins.

In-process inspection takes place during production, either on the assembly line or throughout the manufacturing stage. This step verifies that proper testing procedures are being followed, and that quality standards remain consistent with customer expectations.

Pre-shipment (final) inspection occurs once production is completed. Inspectors review a sample of finished goods to confirm they meet quality criteria before shipment. Depending on the results, the shipment may be approved, rejected, or placed on hold for further review.

We use internationally recognized sampling standards to determine how many units will be randomly selected for inspection. Typically, we follow the ANSI Z1.4:2003 guidelines, which assign a code letter based on the total order quantity. That code then identifies the appropriate sample size according to the selected sampling plan, most commonly single or double normal sampling.

If you do not already have a sampling method in place, we’ll help you choose the most suitable plan for your product and inspection goals.

During the inspection, samples are evaluated against a detailed checklist covering appearance, functionality (where applicable), packaging quality, labeling, and overall workmanship. If you do not yet have a formal inspection checklist, we can prepare one for you.

Every defect found is categorized as critical, major, or minor based on the agreed inspection criteria. The results are compared to the AQL (Acceptable Quality Level) limits, which determine whether the batch passes, fails, or requires further action.

ANSI Tables reference

An AQL (Acceptable Quality Limit) represents the maximum percentage of defects that can be considered acceptable during a quality inspection. Separate limits are typically set for critical, major, and minor defects, with each category having its own allowable threshold.

For example, a common inspection standard might use the following AQL levels:

The lower the AQL value, the stricter the inspection—meaning fewer defects are permitted in the approved sample.

When establishing AQL levels, it’s important to find the right balance. Setting the levels too low may result in frequent shipment rejections and production delays, while setting them too high risks allowing defective products into the market.

A shipment is rejected when it clearly fails to meet the defined inspection standards. A hold shipment decision is used when the issue is not clearly defined or is subjective, requiring further review or clarification before approval.

The AQL establishes numerical limits for acceptable defects in a sampled batch, categorized as critical, major, or minor issues. Each of these criteria represents a specific type of defect and is defined by the impact it has on the product’s safety, functionality, or appearance.

Clear and well-defined criteria are essential for accurate inspections, as they guide inspectors on what to evaluate and how to classify any issues found. These standards may be set by international guidelines, industry practices, the quality engineer’s expertise, or specific buyer requirements.

SS Quality Inspection provides secure online reporting and scheduling services. All inspection reports, along with supporting files such as digital photos and documentation, are uploaded to a protected online portal. Clients receive confidential access to view, download, and manage their information conveniently and securely.

Audits help uncover weaknesses or gaps within a company’s management and production systems that could result in quality issues. By identifying these risks early, audits enable management to take corrective action before defective products are produced. Because of their preventative nature, audits are widely used when evaluating and selecting reliable suppliers.

First-article inspections catch compliance issues right at the start of production, ensuring new products meet requirements before full manufacturing continues.
In-process inspections spot problems as they arise on the production line, allowing quick corrections and reducing the time and cost associated with reworking finished goods.
Pre-shipment inspections verify product quality before goods are dispatched, helping prevent defective shipments and avoiding delays, returns, or replacement costs for the buyer.