In the complex choreography of global manufacturing, quality assurance isn’t a one-time event; it’s a continuous process that unfolds at every critical stage. While Pre-Production Inspections (PPIs) lay the groundwork and Pre-Shipment Inspections (PSIs) serve as the final gate, there’s a crucial checkpoint in between that often determines the ultimate success of an order: the During Production Inspection (DPI), also known as an In-Process Inspection.
At The Inspection Company, we recognize the immense value of DPIs. This isn’t just about catching errors; it’s about course-correction, optimizing processes, and preventing widespread defects while the majority of your order is still being manufactured. This blog post will delve into How to Ensure Quality During Production Inspections, offering actionable strategies for both buyers and suppliers to maximize the effectiveness of this pivotal quality control measure.
Understanding the During Production Inspection (DPI)
A During Production Inspection (DPI) typically takes place when a certain percentage of your order has been completed – usually between 10% and 20% of the total production volume. At this point, the initial production kinks should have been ironed out, and the factory should be in full swing.
The primary objectives of a DPI are to:
✅ Verify Initial Production Quality: Assess the quality of the products already manufactured to ensure they meet specifications.
✅ Identify Recurring Defects: Detect any recurring issues or deviations that might indicate problems with the production process, machinery, or materials.
✅ Monitor Production Schedule: Check the factory’s progress against the production timeline.
✅ Assess Internal QC Procedures: Observe the factory’s own quality control processes on the production line.
✅ Implement Corrective Actions Early: Provide an opportunity for immediate corrective actions to be taken before the entire order is completed with defects.
Think of a DPI as a critical mid-course review. It’s your chance to check the compass, adjust the sails, and ensure your ship is heading in the right direction before it’s too late.
How to Ensure Quality During Production Inspections
Maximizing the effectiveness of a DPI requires a concerted effort from both the buyer and the supplier. It’s a partnership aimed at delivering excellence.
- Clear Communication and Detailed Specifications (Buyer & Supplier Responsibility)
Just like with a PPI, crystal-clear communication forms the bedrock of a successful DPI. Ambiguity can lead to misunderstandings and missed defects.
For Buyers:
✅ Provide Full Documentation: Ensure the inspection company and the factory have the most updated and comprehensive set of specifications, technical drawings, approved golden samples, color codes, packaging requirements, and any specific performance criteria.
✅ Define Critical Quality Points: Highlight specific features, dimensions, or functionalities that are particularly critical to your product’s quality and performance. This helps the inspector focus their attention.
✅ Communicate DPI Purpose: Reinforce with the factory that the DPI is a collaborative effort to ensure smooth production and prevent large-scale issues, rather than just a pass/fail audit.
For Factories:
✅ Thorough Understanding: Ensure your production team, line supervisors, and internal QC personnel fully understand all buyer specifications and critical quality points.
✅ Immediate Clarification: If any specification is unclear or ambiguous, seek immediate clarification from the buyer before production begins.
Why it matters for DPI success: The inspector will use these specifications as their primary reference. Any lack of clarity can result in misinterpretations and failures to identify non-compliance.
- Ensure Sufficient Production Completion for Inspection (Factory Responsibility)
A DPI can only be effective if there’s enough product to inspect. Scheduling it too early can lead to insufficient data, while scheduling it too late misses the opportunity for early intervention.
✅ Reach Agreed-Upon Percentage: Do not schedule or allow the DPI to proceed until the agreed-upon percentage of goods (e.g., 10-20%) is genuinely completed and ready for inspection. This means finished or near-finished items, not just components.
✅ Segregate and Prepare Goods: Have the completed units moved to a designated, well-lit, and accessible inspection area. These units should represent the actual production run, not hand-picked “good” samples.
✅ Provide Adequate Space: Ensure the inspector has enough clear table space, chairs, and good lighting to perform their checks. Access to power outlets may be needed for functional tests.
Why it matters for DPI success: The sample size for a DPI needs to be representative of the ongoing production. Insufficient or unrepresentative samples can lead to skewed results and a missed opportunity to catch systemic issues.
- Facilitate Access to Production Lines and In-Process QC Records (Factory Responsibility)
A key aspect of a DPI is observing the actual manufacturing process and the factory’s internal quality control points.
✅ Allow Production Line Access: The inspector should be allowed to walk the production lines, observe manufacturing processes, and potentially select samples directly from the line, not just from a finished goods area.
✅ Share In-Process QC Documents: Make your internal QC checklists, work instructions, in-process test results, and any corrective action records readily available to the inspector. This provides insight into the factory’s own QC efforts.
✅ Assign a Knowledgeable Contact: Designate a factory representative (e.g., QC manager or production supervisor) who can accompany the inspector, answer questions about processes, and retrieve specific batches or documentation as needed. This person should have the authority to make decisions if minor issues arise.
Why it matters for DPI success: A DPI goes beyond just product checks; it evaluates the process. Access to the production floor and internal QC data allows the inspector to identify systemic issues that might be causing defects.
- Be Prepared for On-Site Testing and Observation (Factory Responsibility)
DPIs often involve more than just visual checks; they can include functional testing, measurement verification, and observation of critical processes.
✅ Provide Tools/Equipment: Ensure access to factory tools that might be needed for the inspector’s checks, such as measuring tapes, calipers, weight scales, or specific jigs.
✅ Functional Test Setups: If functional tests are part of the inspection scope (e.g., plugging in an electronic device, operating a mechanical part), ensure the necessary power, water, or other resources are available for the inspector to perform these tests.
✅ Assistance with Disassembly/Reassembly: For certain products, the inspector might need to partially disassemble a unit to check internal components. Be prepared to provide assistance for this, as well as for re-packaging.
✅ Observe Workmanship: The inspector will be looking at workmanship quality on the line. Ensure that operators are following best practices and that any rework procedures are being handled correctly.
Why it matters for DPI success: Comprehensive checks are crucial. Being prepared for functional tests and allowing process observation ensures a deeper dive into quality, rather than just superficial checks.
- Act Swiftly on Inspection Findings and Implement Corrective Actions (Buyer & Supplier Responsibility)
The true value of a DPI lies in the immediate action taken based on its findings. This is where quality improvement happens.
For Buyers:
✅ Prompt Report Review: As soon as you receive the DPI report from The Inspection Company, review it meticulously. Pay immediate attention to any “pending” or “fail” findings.
✅ Decisive Action: Communicate clear, actionable instructions to the factory. If major defects are found, halt production until corrective actions are confirmed. If minor, specify how they should be rectified.
✅ Follow-Up Verification: If significant issues were identified, consider requesting a follow-up visit or photo verification of the implemented corrective actions before allowing production to continue.
For Factories:
✅ Immediate Corrective Action: Do not wait. If the DPI identifies issues, take immediate steps to address them on the production line. This might involve re-training staff, adjusting machinery, or isolating defective raw materials.
✅ Root Cause Analysis: For recurring issues, conduct a thorough root cause analysis to implement effective corrective and preventive actions (CAPA) to avoid recurrence.
✅ Communicate Actions: Provide timely updates to the buyer and the inspection company on the corrective actions taken, along with evidence if possible (e.g., photos of reworked items, updated process flows).
Why it matters for DPI success: A DPI is a warning system. Ignoring its signals is akin to ignoring a fire alarm. Swift and effective corrective action is paramount to preventing a small problem from becoming a catastrophic failure for the entire order.
Conclusion
The During Production Inspection is a vital, proactive step that can save your business immense time, money, and reputational damage. By systematically applying these strategies, both buyers and suppliers can transform a DPI from a mere compliance check into a powerful tool for continuous quality improvement.
At The Inspection Company, our experienced inspectors are trained to be your eyes and ears on the ground, providing objective, detailed insights into your production quality at this critical mid-stage. We empower you to make informed decisions and ensure that your final product not only meets but exceeds expectations. Don’t let defects multiply unchecked. Contact us today, and safeguard your quality every step of the way.
