Pre-production, during production, pre-shipment, loading check, factory audit: which inspection answers which question

An inspection answers one question at one moment. Ordering the wrong type gives a clean report on a question you did not need answered. The names below are the ones commonly used in the trade; they are usual practice, not definitions from a standard, and the scope of any inspection is what you and the inspection company put in writing.

The five types

Factory audit

It takes place before you place an order, or on a schedule you set. The auditor checks that the factory exists as described and looks at its licence, production lines, equipment, quality records and capacity.

It tells you about the factory. It does not tell you whether a particular order will be good.

Pre-production inspection

It takes place before production starts, once materials have arrived. The inspector checks that the materials and components match the approved sample and the bill of materials, and that the production plan fits the shipment date.

It tells you the factory is about to make the right product. It does not tell you how the finished goods will turn out.

During production inspection

It takes place when part of the order is finished and the rest is still on the line. The inspector compares the first finished units with the approved sample, looks at the factory's own in-line records and lists the defects appearing so far.

It finds problems while they can still be fixed. It says nothing about units not yet made.

Pre-shipment inspection

It takes place when the order is finished and most of it is packed. The inspector draws a random sample from the lot and checks workmanship, dimensions, function, labelling and packing against the specification.

It tells you whether the sample meets the specification. The result is based on a sample, so it is not a statement about every unit. How many units are pulled and how many defects are acceptable comes from the sampling plan you agreed; an AQL sampling calculator gives the numbers for a lot size.

Container loading check

It takes place at the factory or warehouse while the container is filled. The inspector looks at the container, counts the cartons against the packing list, watches how they are loaded and records the seal number.

It tells you the right cartons went into a sound container. It does not tell you what is inside the cartons unless a product check is added.

Choosing

Work back from the risk you are worried about.

• A new supplier you have not visited: a factory audit before the order.
• A new product or new materials: a pre-production inspection.
• A long production run or a tight date: a during production inspection.
• Any order where you pay the balance before shipment: a pre-shipment inspection.
• Mixed products in one container, or a history of short shipments: a loading check.

Types can be combined. A pre-shipment inspection followed by a loading check covers both the goods and what was shipped.

The checklist generator builds a starting checklist for each type.

Questions

Is a pre-shipment inspection enough on its own?

It is the most commonly ordered type because it comes just before payment and shipment. It finds problems late, when the only remedies are rework or delay. Earlier inspections exist to find the same problems sooner.

Does an inspection certify the product?

No. An inspection report records what an inspector saw on a sample on one day. Certification and laboratory testing are separate activities.

Who decides the scope?

The buyer, in the inspection instructions. The inspector works from the specification, the approved sample and the checklist you provide.

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Sources: this article describes common trade practice and cites no external data.