Quality Products International

El mejor modo de asegurar que la producción marcha con suavidad es estar allí…si no puede estar allí por sí mismo, nosotros podemos estar allí por Ud. ¡Sus ojos y sus oídos, in situ!

QPI Ltd es su socio de confianza en control de calidad en Asia

Para mitigar cualquier imprevisto, hacemos seguimiento de los hitos clave del proceso de producción, incluyendo:

• Pedidos de materias primas
• Chequeo de materias primas pre-almacenamiento (Inward Quality Control)
• Inicio de la producción
• Inspecciones durante la producción (DUPRO), bien en hitos clave o de una forma continuada a diario durante el proceso de producción
• Puntos críticos de control
• Test de muestras por lotes /AQL
• Toma de muestras
• Supervisión de embalaje / carga contenedor
• Inspección pre-embarque
• Contratación del transporte

…toda la información es actualizada en tiempo real, accesible por Ud. a través de su login personal / de empresa y puede ser enviada directamente a su email o móvil en momentos clave predeterminados del proceso de producción.

Numerosos clientes se apoyan únicamente en las inspecciones pre-embarque. Lamentablemente, entonces puede ser demasiado tarde para remediar pequeños errores que destinen el envío al fracaso. QPI Ltd propone una solución de gestión global, en la que nos hacemos cargo de todo el proceso de manufactura, desde la pre-producción a la manufactura y logística. Un servicio que proporciona tranquilidad, al saber que sus intereses están protegidos en su fábrica de China, Vietnam, Camboya o Laos.

QPI Ltd ofrece un amplio rango de paquetes que se ajustan a diversos presupuestos. Estamos seguros de poder satisfacer sus necesidades a un coste que compensa sobradamente los riesgos que se evitan. La verdadera recompensa es que ahora Ud. se podrá despreocupar de sus procesos de manufactura en Asia y se podrá dedicar a otras áreas críticas para su negocio.

QPI Ltd Español: Acerca de QPI Ltd

QPI Ltd Español: Inspecciones de calidad en China (esta página)

QPI Ltd Español: Aprovisionamiento en China

QPI Ltd Español: Tests de laboratorio

QPI Ltd Español: Materias primas a granel

QPI Ltd Español: Desarrollo de productos

Quality Products International (QPI Ltd) es una compañía de propiedad australiana, con base de operaciones en China y oficinas en Hong Kong, Europa y Estados Unidos. QPI Ltd ofrece servicios por toda Asia, con un fuerte enfoque en fabricación y control de calidad en  China. Las operaciones en China son gestionadas por un equipo mixto local y expatriado.

Poseemos amplias competencias que abarcan desde el desarrollo de productos a los controles de calidad pre-embarque, así como la gestión de todas las fases del proceso de producción que median entre ambas.

Nuestra experiencia proviene de la posesión, gestión y fabricación de nuestras propias marcas, así como de nuestra asistencia a los propietarios de marcas en la maximización de sus objetivos a través de producción OEM de alta calidad.

Nuestros servicios incluyen:

• Desarrollo de productos
• Detección / auditoría / selección de fábricas
• Seguimiento de la producción
• Inspección de calidad en China y Asia
• Test y certificación de productos con nuestros socios acreditados

Por favor, no dude en contactarnos para asesorarle en cualquiera de los citados servicios en China y Asia.

QPI Ltd Español: Acerca de QPI Ltd (esta página)

QPI Ltd Español: Inspecciones de calidad en China

QPI Ltd Español: Aprovisionamiento en China

QPI Ltd Español: Tests de laboratorio

QPI Ltd Español: Materias primas a granel

QPI Ltd Español: Desarrollo de productos

A Container Loading Inspection involves an inspector checking that the correct product is loaded safely into the container typically before it leaves the factory.

It is conducted after and normally separately to other inspections such as PSI.

Once the  container is loaded it is fitted with a tamper evident security seal before leaving the factory.

Always consider a Container Loading Inspection

Container Loading Inspections should seriously be considered for first shipments out of a new factory. Especially if that factory has not been vetted or subjected to an audit, credit or background check.

These inspections are especially relevant if there has been a dispute or QC concerns with a shipment.

Many clients query why a container loading inspection is required and / or why that cannot be conducted by the QC inspector as part of the Pre Shipment Inspection (PSI).

Container Loading Inspection is an additional safety check

If a client has some concern about the factory they should seriously consider a Container Loading Inspection.

It is a wise option for new factories and / or if something appears a little “off” or there is some suspicion.

It is especially wise, if there has been a significant QC issue on a shipment and it should be considered mandatory if there has been a major disagreement with a factory or supplier.

Typically payment occurs sometime between product completion and arrival at the clients warehouse.

Once the Pre Shipment Inspections (PSI) results in a PASS report, to confirm the product meets requirements, the goods are normally stored in the factory warehouse. The shipping is booked and a container dispatched from the shipping company to the factory for loading.

The main risks are that:

- goods may  not be loaded correctly and with due care

- the correct goods are not loaded, or

- no goods are loaded!

Poor Container Loading

This should be easy, and normally is a simple process that goes smoothly. If the factory has a sound QC system, they should take due care of loading as well….and often do!

In busy periods container loading is sometimes completed by small teams of contract workers or day laborers. They have had no part in the careful construction of your product and will be long gone by the time you find they have mishandled it.

Similarly the truck driver either of their own accord, or at the direction of the shipping company will often pressure the loading crew to load the container as quickly as possible so the truck can complete the delivery to the shipping yard as soon as possible, again with no real regard for your product.

If the goods are delicate obviously due care should be taken, if it is a mix of heavy and light products, the container should be loaded with heavy at the bottom.

However, it is often the case that if left unsupervised, other factors will determine what happens.

Often the box closer to the warehouse door will be the first into the container and may well be crushed, if it should have been top loaded.

Containers will often be “layer loaded” so the entire floor is filled, and the workers walk the next layer in on top. Sometimes walking boards are placed to protect each lower layer, either way, sometimes the lower layers are simply damaged.

Cartons are often sent down chutes on the side of buildings to move it from the upper level of a warehouse to the truck. It is often with no damage and unfortunately sometimes with no care.

We have seen containers opened at distribution centers that were loaded just on one side of the container, leaving most of the container empty. As that narrow stack of cartons fell during transit, much of the product was damaged as the corners of some cartons landed on the sides of others.

Similarly is not uncommon to see containers packed so tightly, product is damaged as it wedged in. It is  better choose between shipping a small percentage in the next consignment, by LCL or even leaving behind, rather than damage most of the product in the consignment.

…again, often all goes well. The question is, how important is the consignment to the client, and how much is the reliability of the factory proven?

Poor product or no Product Loaded

If there has been dispute about QC, and especially if extensive re-work has been required it needs to be checked!

Often a follow up PSI will be conducted…..BUT….

It is quite possible that poor quality product is mixed back into the shipment after the PSI.

….again, normally the PSI is completed in a day, the inspector leaves the factory and container is loaded a following day.

As part of the container loading inspection, a smaller number of random boxes are rechecked to confirm they contain the correct product.

Sometimes it can be even more sinister.

On one consignment of Flat Screen TV’s, the factory loaded the container before the inspector arrived. The factory reluctantly unloaded some boxes which appeared OK and were obviously for the benefit of customs should they inspect on export as they sometimes do.

After much reluctance on the part of the factory more boxes were unloaded to reveal that most boxes in the container were void of any TV’s with some rocks in each to make up enough weight to avoid raising suspicion.

To be fair to most factories in China, this was an extreme and rare case. The factory had not been vetted or checked. The client simply found a “good deal” on line, paid the deposit and would have paid (and lost) the full value of the shipment if not for the inspection!

So why not complete both PSI and Container Loading Inspection on the same day? There are typically two complications with trying to complete both on the same day.

PSI is normally a full day on its own

To optimize the PSI, it is normally designed to fill one man day. The aim is to inspect the maximum number of items in line with the checklist that is designed to ensure the clients requirements have been met.

A thorough inspection requires complete focus and no distractions.

There may be scope to trim down an inspection so that there is time to supervise loading in the same day, and QPI Ltd is open to doing that, if it is the particular wish of the client, however the container booking logistics also need to be considered.

PSI is normally conducted a few days before container loading

Neither the factory or the shipping companies are keen to have containers at factories for longer than required.

The container loading is normally booked once a PASS report is confirmed. The truck carrying the shipping container is sent from the shipping yard to the factory and the truck waits at the factory while the container is loaded.

If the client wants the container loaded on the same day as the PSI, there is a risk that PSI will result in  a FAIL and consignment will be rejected. The container booking is then wasted and the truck returns with an empty container to the shipping yard.

Obviously there are costs involved with the aborted booking. Typically they are a few hundred dollars.

If production / inspection / shipping the deadline is tight, it is certainly worth considering! The client will normally have to commit to paying the extra container booking / trucking charges should the PSI result in a FAIL of serious PENDING report, and obvious delays, however it can sometimes ensure that a shipment sails on time.

Normally there is a window of a few days between inspection and shipping. If that is the case and there are any reasons to consider a container loading inspection, it will probably be cheaper to pay for the container loading inspection than the container return and re-booking fee…..or the other costs associated with risk to the integrity of the shipment.

Most major retailers and brand managers require factories to be audited, both for ethical trading reasons and confirm the quality / capacity capabilities of the factory to manufacture the product to the standard required.

QPI Ltd can conduct such audits where required.

However a full formal audit is not always mandatory. In that case the client may consider not conducting audit as they can be quite expensive. The big problem is that sometimes that means the factory vetting process is neglected completely and sometimes with serious consequences.

Without some process to vet, verify or check a new factory or supplier, clients put themselves at real risk.

Most orders require a significant deposit, which is a large financial commitment and there are issues such as IP, or even complications like one “off samples” or tooling being sent, but not returned.

QPI Ltd has some options that are far more cost effective than a full formal audit but still protect the clients interests and mitigate many of the risks.

Comfort Check

Many clients just want to know that the factory exists  and can produce what will be ordered.

The idea of the comfort check is something a much more professional than asking a friend to drive past, and a lot less expensive than a full audit.

Many “factories” on the internet are nothing more than a “trading company” operating out of a bedroom, or one type of factory trying to sell other products from another factory, to widen their customer base, or drum up additional business.

….all of which may or may not be acceptable to a client, however it is good to know what the true situation is.

The QPI Ltd comfort check can confirm that the factory exists, and appears capable and in good order.

We can confirm that they have the facilities needed to make the products being considered, check they have QC procedures in place, observe the level of workmanship to see that comparable products and quantities are being produced.

Credit Check

While common in most parts of the western world, they are a little more complicated and less accessible in China.

…..however still very necessary.

QPI Ltd can conduct credit checks & company reports on companies in all provinces of China at competitive rates.

Something worth considering before sending large sums of deposit money to contact found on the internet!

After Vetting

Obviously the follow up of a well defined product brief as well as considerations to QA/QC, lab testing and inspections such as DUPRO (During Production Inspection), Pre Shipment Inspections (PSI) and  container loading inspection should be considered.

Pre Shipment Inspection (PSI) are a key component in any thorough QC programs. They should normally follow a predefined checklist, which details the specific elements that need to be inspected and the importance (minor, major or critical) of non conformance.

The PSI is normally conducted as Final Random Inspection (FRI) typically at a pre-determined AQL level that defines the percentage of the product checked, and acceptable level of non-conformance.

The PSI can be conducted as a full 100% inspection, though that can often be prohibitively expensive. Especially if conducted with a thorough check list. (As the checklist details the number if elements to be inspected, and thus the time needed.)

Where 100% inspection or some type of “in factory testing” is required it can sometimes be more effectively completed as DUPRO (During Production Inspection) with an independent inspector supervising testing conducted by the factory staff.

The FRI / PSI is very widely implemented and rightly so. Once the factory is paid and the goods are shipped there is often little or no (effective) recourse with the supplier.

It should only be relied on when the client is confident that the factory is reasonably honest, has a good grasp of and capability to produce what is required.

Some possible shortfalls with a Pre Shipment Inspections that many clients fail to consider are:

-         It does not protect the clients deposit (in the case of an unscrupulous or unreliable factory) – supplier vetting is required

-         It will not ensure goods are made to standard, specification or other requirements – testing, DUPRO etc is required

-         There is a risk of switch out after the inspection (in the case of an unscrupulous factory) – container loading inspection.

In a procurement environment, the PSI will simply define the scale and scope of the problem and protect the client from paying full balance for, shipping and receiving deficient product.

…or worse, if the product is shipped direct from the factory to the manufacturers final client!

Typically if a problem is found during a Pre Shipment Inspection, there will be strong pressure to meet a shipment deadline. That pressure is normally both from the client and the factory.

The client normally has some delivery deadline, particularly if it is seasonal, sold to a major retailer, tied into a promotion, designed to sell with other products, etc, etc

The factory is keen to clear their warehouse space for other product, and get paid!

It invariably leads to complications, all of which can be mitigated through better product specification in conjunction with DUPRO inspections.

DURPO or DURing PROduction inspections are one of the most valuable and cost effective elements of a robust QC system. It should not normally replace Pre Shipment Inspections (PSI), DUPRO can certainly improve any QC system in a very cost effective.

Quite simply DUPRO gives the client an opportunity to know and understand what is happening with their order during production and affords the opportunity address, redress or rework production in a more timely and cost effective manner, often before shipping deadlines.

The mainstay of product inspections is the Pre Shipment Inspection (PSI)

In a procurement environment, the PSI is akin to seat belts and insurance policies for drivers and they all offer very good protection.

However just like with insurance policies and seat belts, when all goes smoothly there is no issue, however once needed things will be messy.

In most cases the PSI will simply define the scale and scope of the problem / accident and protect the client from paying for deficient product.

…..better to take steps to avoid the accident in the first place!

Typically if a problem is found during a Pre Shipment Inspection, there will be strong pressure to meet a shipment deadline.

The decision structure is often to:

- ship or

- rework.

If shipping inferior product, should a discount be allowed?

If rework is decided, who will pay for rework? Client, factory or intermediary?

If the fault is “compliance related” the decision process will have to account for the need of products to comply with relevant standards.

Original specifications, artwork, purchased orders and emails will be scrutinized by all parties involved. Bluffing and brinkmanship is common by both factory and client with intermediaries typically trying to minimize their own exposure.

If the client feels their product is “worthless”, especially if non compliant, they may well forfeit their deposit, but then the question comes up about goods in the factory, often bearing the clients trademark!

….I have been involved in supervised product destruction on a few occasions, and it is often a tricky process.

If a factory feels that re-work will cost more than their profit margin, they may well turn their back on the client with a view of disposing the product “elsewhere” to recoup some funds.

Both factory and client will rightly feel that they have legal rights….again once the Pre Shipment Inspection alerts the client to the problem it will by definition be a problem and it is often a messy one that will be expensive in some way to resolve.

DUPRO is not a guaranteed fix, but like defensive driving practices, it will reduce the risk of the accident (or PSI failure) and in many cases reduce the damage of an accident.

Even a single DUPRO inspection can make a massive difference, and on larger orders it can be worth considering more man days of DUPRO rather than more man days or PSI.

The timing of the DUPRO should ideally be at a key point in production & / or somewhere late in the production cycle – early in the packing cycle.

It also sends a clear message to the factory that the client is serious about QC!

Key Point DUPRO

With our genesis in Floaties Swim products QPI Ltd has been involved in a lot of inflatable and swim wear manufacture.

Typically both PVC and fabric go through a similar process, where they are purchased in rolls of material which is often a specific colour / texture that has been ordered for that product.

Raw material is cut into sheets for printing and then sewn or welded into a finished product.

If the print is inferior, it will have a significant impact on the final product, in some cases such as inflatable swim products, poor or incorrect print may render the product non-compliant which means it will not legally be sealable in the target market, with jail terms possible in some cases!

Re-work for this will typically be impossible / non-viable, or at best look terrible. Scrapping the product has costs associated and the lead time to order new raw material and start again, will normally mean losing market position in a seasonal market.

For us the benefit of having someone checking the size, colour and artwork of the print, early in the print cycle obvious.

Another good time for DUPRO is during “in factory testing”.

All inflatable products such as Floaties, Hydro Kids and the OEM products that we work with, are subjected to 100% “open valve inflation test”.

There can be merit in having independent supervision of this stage in the process.

……we have seen factories complete 100% inflation test, and then simply pack all product, good and bad for shipment!

General DUPRO

On larger orders, it is worth considering additional DUPRO inspections.

The main two benefits that DUPRO offers, is preventing quality problems before they occur in production and the opportunity to re-work before some element is locked into a final assembly.

It also gives the inspector an opportunity to review factory QC documents and ensure QC procedures have been implemented and followed!

It gives the inspectors an opportunity to see a lot of product, and it underlines to the factory, from supervisor to machine operator that care and attention to detail is needed for that shipment!

There are pros and cons on exact timing of general DUPRO. Earlier in the manufacturing demonstrates QC to the factory and their staff, but will see less product.

Later in production, more product will be seen however there is less opportunity to address it. An ideal time is when most production is complete and packing is starting.

For some items that will have a number of consignments, and / or repeat orders, it is worth considering high DUPRO along with PSI on initial shipments tapering down over subsequent orders.

Post CNY DUPRO

Many factories are staffed by migrant workers, who normally go home for CNY and often consider career, work or factory changes with the start of the next year. It is very common for the majority of factory floor workers, many factory supervisors and even middle management to be NEW to a factory after Chinese New Year!

Many clients find that a number of orders go smoothly and they become comfortable with a factory (and complacent with QC) then shipments after CNY have problems. Often it is the case that there has been a significant turnover of staff, and those familiar with the product / production are no longer there.

…it is virtually like the order has gone to a new factory, even though it is the same location, with the same owners!

Summary

DUPRO is a valuable and cost effective part of a robust QC process.

While DURPO does normally replace PSI, it can often be more effective at improving the quality of product shipped, rather than simply defining and quantifying the problem, which is of sometimes the case for Pre Shipment Inspections.