Everything You Need to Know About Initial Production Checks
What is an Initial Production Check?
Initial production checks (IPCs) take place on the first finished pieces that come out of production. They are the first step in ensuring that your supplier will consistently manufacture good quality products.
You can use an IPC to review the effectiveness of the product specifications that have been used up to that point in production. If any problems have arisen, you will be able to fix them early on. Following on from this, you will be able to decide how to move forward with the rest of production.
IPCs can be adapted to suit different products and suppliers. The exact checks that are done will depend on a client’s specific requirements and the product in question.
However, inspections will always help you to gain a detailed view of your product’s:
Construction
Appearance
Functionality and performance
On top of this, issues such as conditions at the facility, raw materials used in production, packaging and workmanship levels are also checked.
IPCs can help to catch a range of issues in production, before a whole production is impacted. Having an IPC conducted is very much in line with good risk management practices and they often help to avoid major issues.
Why are Initial Production Checks So Helpful?
An IPC could help your business to:
Reduce the risk of incurring costs or reputational damage, as a result of failings in production
Double-check that you are receiving the best raw materials and production standards from your supplier
Prevent future delays in production at an early stage
Reduce the risk of disruption in your supply chain
Ensure that you can meet the quality and safety standards in your industry
Initial Production Checks Help the Production Process
Where an IPC is able to identify mistakes and shortcomings at a production facility, the information gathered can be very helpful to those involved in the management of production.
Knowing where problems are occurring early on helps to confirm what better practices a production facility should follow. This will help to ensure good standards for the rest of production.
An initial production check could:
Find Faults
Efficiency is essential in every industry. The earlier faults are found, the less time is lost reworking or replacing incorrect products. This gives factories more time for creating quality goods… and boosting profits.
Reduce Bad Habits
With inspectors checking over the first part of a production line, bad habits that are seeping into otherwise good production can be found. Stopping these early on will save money in the long run.
How is an IPC Conducted?
Inspection companies send their inspectors into your factory at an early stage of production and they inspect your products as they are being produced.
A QIMA inspection includes a number of important standard checks for all products. This is as well as detailed product specific tests and any tests that are specifically requested. We also carry out inspections for a wide range of softlines, hardlines, toys, electronics and food products, and can complete checks to very specific client requirements.
We provide inspection results in a detailed report, with all necessary and relevant supporting information, including photographs. We provide reports on the same day as the inspection is carried out.
What Inspectors Look For
Inspectors will ensure that a production facility is meeting quality standards in a number of different key areas:
Raw Materials
Inspectors are able to check the quality of the raw materials being used. If necessary, they will also check that raw material composition complies with industry standards. As well as this, the quantity of raw materials at the production facility and storage conditions will be checked.
Manufacturing Processes
The number of workers and machines dedicated to production, as well as general conditions at the facility, will be reported with photographic evidence. Our inspectors also provide an opinion on general onsite conditions, cooperation levels and levels of organization.
Alongside this, inspectors will provide information on matters such as how many items are finished and how many are semi-finished. They will also provide an estimate of daily production capacity.
Product Specifications
As part of the normal inspection procedure, product details such as color, dimensions, construction, artwork and labels are checked. These checks are done against samples and/or specifications provided by the client.
Following on from this, specific tests or inspections can be made according to client requirements and the product in question. Qima provides a wide range of customizable checklists, for different product categories that often helps to narrow down the selection.
Inspections are able to provide detailed specific information as requested by each client, for each product.
Packaging
Packaging conformity is checked against client specifications, with the dimensions and weight of export cartons recorded. Following on from this, shipping marks are also checked against client specifications.
Workmanship
Inspectors will check for defects in workmanship. This is done by closely examining products for specific defects.
What Other Inspections are Available?
While having an initial production check done will help to get production off to a good start, it’s best to fully ensure quality with further checks.
An IPC will help you to ensure that your products are being correctly produced at the outset and will allow you to clarify your requirements. However, without further checks, there is no guarantee that these good standards will be maintained right through production.
The complete range of additional onsite inspections offered by Qima is as follows:
QIMA and Your Next IPC Inspection
When you work with QIMA quality inspectors, you gain access to highly trained experts who want to help your business.
Not only can Qima help you run a tight ship during production, but we can help with a wide range of quality control issues. Other services we provide include laboratory based safety and quality tests, supplier audits and certification services.
QIMA can provide you with:
An advanced online quality control process
A comprehensive understanding of your supply chain and your business needs
On-site inspections within 48-hours of request
Same-day inspection reports
Speedy communication and flexible inspection management
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