Samples are often required from factories and suppliers.

It may be to approve shipment, present to end user / clients, or for lab testing.

The big question, is the validity of the test sample, and is it a true representation of the batch as a whole.

Having a QPI Ltd inspector visit the factory or supplier, select a representative sample and ship directly to you or your lab can minimize the risk dramatically.

Lab Testing

A lab report supporting compliance can sometimes be mandatory for particular products being imported into certain markets.

In many cases China customs may reject export of the shipment if an appropriate pass report is not included in paperwork.

Of course same may happen on arrival at the destination port, however there is real pressure on the factory to ensure that a pass report is produced to get payment, and ship the product out of the factory and out of the country!

…and the temptation to sneak samples in that are more likely to pass compared to the rest of the consignment is very real!

Most clients will take the management of the testing away from the factory and either assign a 3^rd party QC company such as QPI Ltd to manage the testing, or deal directly with the lab themselves.

IQC Raw Material Samples

In some cases it is most practical to test the individual raw material, and can best be done as an “Inward Quality Control”. That avoids the raw material contaminating & / or accumulating costs in product that will ultimately be rejected.

It also allows for timely re-order of the raw material.

Product Samples

These can be collected in a late stage of production, typically before final packing. Again an independent inspector can ensure it is both random and representative of the other product.

Post Consumer Testing

Products will often be tested after shipment and sale, which is entirely out of the client / manufacturers control.

It may be tested by competitors or consumer groups.

Sometimes by authorities, especially if there is consumer related safety incident or accident involving the product.

Even some very large players such as Apple, Disney and McDonalds have been caught out!

Contact QPI Ltd to find out more about one of our inspectors visiting the factory to ensure the sample is legitimately drawn from the batch of raw material or mass production, rather than a “specially prepared sample”.

We can also assist in lab testing through one of our partner labs in China, Hong Kong and other parts of the world.

See related articles about McDonalds, Disney and Apple.

Also Physical lab testing, and Chemical lab testing by some of QPI Ltd’s lab partners

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.

Some clients ask if a check list is necessary and sometimes ask QPI Ltd to complete the check list for them.

The simple answer is that they are vital!

Yes QPI can certainly assist in preparing an inspection check list and in fact our supervisor staff and inspectors work on this together prior to all QC inspections.

The checklist is the key to successful ”inspection mission”.

Just reiterating on this point.

The check list is like a map for us and our inspectors.

…without we are “flying blind”.

While it is fair to say “The more detail the better”, however the client need not be intimidated by the formal term.

At very least, a list of what is important to them. It should normally evolve out of the clients specifications to factory.

It is very difficult to know what was requested, and what is important to the client without some guidance from them.

In the garment trade, products such as denim pants are a good example of some extremes.

Think of an order for Jeans, without an indication if they are normal Jeans compared to “acid wash” jeans.

Some years ago, once jeans got some holes or rips in them, they would be discarded.

Now acid wash / stone wash etc, jeans are sold new, with holes and tears.

…while it is an extreme example, without a check list or guidance from the client, the inspector would have NO clue about which to reject or pass.

QPI inspectors obviously have an eye for detail and always wish to ensure that the client is getting the quality they expect, a checklist, is basically just a way for the inspector to know what the client expects and what is important to them!

文章简体中文 – 文章繁體中文

Quality Products International Limited (QPI Ltd) is a western owned and managed Quality Control and Product Development company with a head office in Hong Kong and an operational base in Shenzhen, Guangdong.

With recent growth, QPI Ltd needs additional qualified QC Inspectors and Auditors to visit factories of our foreign clients in the provinces of Shanghai and JiangSu, as well as the North East of Guangdong province, in areas such as Chaozhou and Shantou.

Quality Products International Limited is conducting QC work in Shandong province.

We are looking for qualified and experienced hard-line inspectors and Auditors in Shandong province for part-time work.

Timing would range from sporadic to several days per week.

If you are qualified, experienced, based in Shandong and available for part-time / freelance work, please contact QPI Ltd.

Many people in the industry use reference to major brands such as Disney as a hallmark for their own quality credibility.

Most self respecting trading companies will have at least one Disney product in a prominent position in their showroom.

The story in the Shanghai Daily is a stark reminder of need for proactive vigilance in QC.

While there is almost certainly a “back story”, manufacturers and brand owners / managers can certainly take one thing away from the story. If you brand is associated with QC failure it will quickly tarnish your reputation!

Disney products fail watchdogs’ quality tests

DISNEY products were among the 10 percent of children’s clothes, shoes and toys that failed recent quality tests, city watchdogs said yesterday.

Officials said some clothes tested may cause skin allergies, as they had a higher pH index than the country’s standard. A pair of Roberta di Camerino children’s pants was found to have a pH index of 8.4, well above the 7.5 upper permitted limit, said the industrial and commercial bureau.

Products that failed to meet standards have been removed from shop shelves, officials said.

Full Story:  Shanghai Daily

Two broad comments spring to mind.

Firstly to be fair to Disney, the details are scant! There is so much “knock off” product and “factory second” / reject product on the market, that the product discovered by the “watch dog” may well be product from a rejected shipment.

The “Micky & Friends” Fireworks in the QPI Ltd CNY blog are a prime example of something probably not compliant and well out of Disney’s control, yet clearly (and falsely) associated with the brand.

Certainly if you look at Apple, iPhone, iPad etc, there is a plethora of product available that is branded Apple, however it would be fair to say it more “inspired by” Apple than a genuine Steve Jobs creation!

Secondly, and more importantly, the article is a stark reminder about the need for vigilance in QC.

It is something that can become tedious, and may be seen as an expense, however the process and costs associated can be managed! There are many well qualified companies that can support the process in a cost effective manner.

QPI Ltd has packages to assist in managing the QC liaison with factories.  Our production monitoring package has a very low cost and provides very good value. We can provide some all important DUPRO (During Process Inspection – which gives clients and early warning opportunity for problems, so they can be solved with minimal impact to cost and schedule) as well as the main stay FRI / PSI (Final Random Inspection / Pre Shipment Inspection).

There are of course many other important elements such as supervising sample selection to ensure lab samples are representative of the entire shipment. Of course if the shipment fails, the issue of negotiating rework or destruction and disposal can become complicated and certainly needs a very high level of vigilance!

文章简体中文 – 文章繁體中文

Quality Products International Limited is looking for skilled auditors especially in the Ningbo and Pearl River Delta region that have experience with Auditing to BSCI standard.

Please contact QPI Ltd

Updated toy EU directives introduces elements that manufacturers have seen in standard such as EN13138 for some time now.

It should be noted that the “manufacturer” is typically the brand owner that commissions the manufacture and import rather than the factory in the case of OEM production.

New Obligations for Manufacturers

Manufacturers will be required to ensure that documentation for all their new and existing products meets the new technical documentation requirements. A new requirement is that manufacturers will have to draft an EC Declaration of Conformity (DoC) for each product. This declaration, along with all technical documentation, must now be kept on file by the manufacturer for ten years after placing the product on the market. Along the DoC, product instructions and safety information must be included.

Additionally, products must be marked with the name and address of the manufacturer and the importer, as well as a relevant product type, batch or serial number, and CE mark.

Read Full Article SGS

Connect on Linked In

There was recently a post and discussion on Linked In

What are the best methods to confirm that a Chinese company is a manufacture and not a trading company?

From my experience in china so far I waste too much time trying to verify that a company is a factory and not a trading company. Except visiting the factory, does any one have suggestions on how to check this issue More effectively?

The comments were wide ranging and constructive. The reply I posted was:

A deal may still be workable and in some cases better via a trading company, for the various reasons stated above.

None the less, I think it is fair to know who you are dealing with.

We have at encountered trading companies that swear blindly that they “own”, “have shares in” or have “JV’ed” with a factory making a certain product sample in their show room.

…little did they know that I was family friends with factory owner and knew who owned the tooling in question!

One should also be a little cautious simply sighting paper work. Those people hanging around HQBei Metro exits saying ” ‘piao” can make more than just receipts, and I have seen some excellent “documents” of various formats.

There are two services that QPI Ltd offer.

Company Checks
We offer credit / background checks for companies in most Mainland provinces.

Audits
A full quality / capacity or social / ethical audit that would suit a major retailer can be expensive.

We can offer those, or a simple “lite audit” to provide a basic overview to address initial queries.

Of course the other option is to simply visit the factory.

Even visiting the factory, it can still be difficult to determine for sure if you are in fact “dealing with the factory direct”, or through a trading company that has a close and co-operative relationship with the factory.

At the end of the day, the question is, do you feel comfortable and trust the people you are working with, and does the deal stack up?

Contact QPI Ltd for further information about our services.

See full discussion on Linked In