The samples passed, but the first batch of large goods rolled over-color difference, size out-of-error, wrong packaging, customer claims or even rejects it. This is the most common "win in proofing and lose in large goods."Most of the problem lies in the fact that the inspection before shipment was not carried out properly.This article clearly explains the key points of quality control for the first batch of large goods and the practical operation process of AQL sampling and inspection, and can be followed directly.
1. Why is the first batch of big goods the most prone to accidents?
Proofing and mass production are two completely different production line logics: the samples are carefully crafted by one or two old masters, and the large goods are processed by dozens of workers according to SOP. The first batch of large goods accidents are usually stuck in three links:The batch of raw materials has been changed--The batch of fabrics, toners, and plates used for proofing may not be the same batch during mass production;Workers are not properly trained--Newly opened production lines and newly recruited workers have different movements from samples;No one is watching the packaging process--When the product was ready, the shipping mark was incorrectly printed, the packaging quantity was wrong, and the manual version was wrong, and the ship all capsized in the last mile.
Therefore, the quality control principles for the first batch of large goods are:Press the "worst-case" defense line--First article confirmation, process inspection, and final inspection cannot be omitted.
Second and third passes: first article, inspection, and final inspection
- First article confirmation (when the production line starts):The first complete product after the start of mass production will be checked item by quality control against sealed samples: material, color, size, and process details. The line will be stopped immediately for inspection if the first article fails, and mass production can be carried out only after the first article is signed and approved. This "First Article Confirmation Form" is the benchmark for all subsequent disputes.
- Process inspection (mid-production):Inspection will be conducted once when the batch is about 30% in progress, focusing on whether the problems discovered in the first piece have recurred and whether the quality has drifted after the shift change. Problems found during inspections are corrected on the spot, saving ten times the cost than rework at the finished product stage.
- Final inspection (before shipment):More than 80% of the finished products are completed and more than 80% of the finished products are inspected when they are packed. This is the threshold for determining whether they can be shipped or not, and it is also the focus of this article.
3. AQL sampling inspection: How to read the standard
The internationally accepted AQL (Acceptable Quality Level) sampling standard is used for shipment inspection. The common writing standard in customer contracts is "AQL 2.5 / 4.0", which means:
| the term | meaning | popular understanding |
|---|---|---|
| AQL 2.5 | Acceptable line of Major | For defects that affect use or sales, if the random inspection exceeds the standard, it will be judged as unqualified |
| AQL 4.0 | Acceptable Line for Minor Adverse (Minor) | Small flaws that do not affect functions, with a slightly wider tolerance |
| Critical (fatal) | Safety and regulatory defects | Zero tolerance, if you find one, you will be disqualified. |
The actual operation is carried out in three steps: The first step is to find out from the AQL sampling table according to the batch sizeNumber of samples and number of qualified judgments--For example, 125 products are sampled from 1000 products according to General Inspection Level II, and the Major defect acceptance line is 5 products are accepted and 6 products are rejected; the second step,random drawing box--Draw the square boxes according to the total number of boxes. Draw the boxes at the upper, lower, left, and outer floors, and select the boxes in the corners; the third step,judgment item by item--Appearance, size, function, packaging, shipping marks, and accompanying documents are recorded item by item against sealing samples and customer acceptance standards, defects are classified and counted, and finally conclusions are drawn based on the judgment numbers.
When there are no customer-specified standards, it is an industry practice for general consumer goods orders to be executed according to AQL2.5 (Major)/ 4.0 (Minor), which can be stated in the contract; for products involving safety regulations exported to Europe and the United States, there is always zero tolerance for fatal defects.
4. How to deal with problems detected: three results and three paths
- Accept:If the number of defects is within the qualified judgment number, the goods will be shipped normally. The inspection report is filed, the defect type is fed back to the production line, and the next batch is improved.
- Rework:If you exceed the standard but can be reworked, evaluate the rework amount and time: if you can complete it in advance of the shipping schedule, re-inspect it after rework and then ship it; if you can't catch up, immediately talk to the customer about the delay or batch, and don't take chances and conceal it.
- Concession:Defects do not affect use and sales, and if the customer agrees in writing to make concessions, the goods can be shipped as originally planned-note that it must be a written confirmation from the customer, and verbal consent means no consent. Concession orders are marked with the lot number on the invoice or accompanying documents to facilitate subsequent traceability.
A red line:If the inspection fails and there is no time to rework, you must not default to delivery and then remedy it.If the customer detects damage to the goods, compensation and loss of trust are much more expensive than air freight and delayed delivery.
5. Precipitate the inspection results into standards
Don't throw away every inspection report after inspection: Count the defects by type, find out the first three recurring items, and push them back into the process to correct them-if it is a raw material problem, change the supplier's batch rules, if it is a worker's movement problem, supplement the SOP and training, if it is a packaging problem, make up the packing instructions into pictures and text and post them at the workstation. After three to five batches of goods are completed, the factory will form its own "Common Defects List" and corresponding inspection priorities, and the rollover rate of the first batch of large goods will be effectively reduced. Quality control capabilities are accumulated in batches in this way.
common problems
1. 1. The customer requires a third party to inspect the goods. Who will pay for it?
Industry practices are divided: For the third-party inspection company designated by the customer, most of the fees are negotiated by both parties. The common practice is to pay half each for the first time or the customer bears it, and the factory bears it after long-term cooperation. No matter who pays, the factory should send someone to accompany the whole process, confirm the defect determination on the spot, and provide evidence on the spot if there is any objection, and don't wait for the report to come out before arguing.
2. 2. How to implement a small factory without a full-time inspector?
The key to arranging quality control or production supervisors to follow this process is that the number of samples will not shrink and records will be recorded in a unified form. You can also entrust in-factory inspection services to purchase on a one-time basis with the customer's consent. What is more important than equipment is independence: the person who inspects the goods cannot be the person who records merit for his own production line. Even if he is part-time, the judgment must be independent.
3. 3. If the AQL judgment fails, what should the customer do if he wants to conduct a full inspection?
Full inspection means cost, so calculate the account first: compare the working hours and expenses of full inspection with concessions and discounts, whichever is lower. If a full inspection is carried out, the inspector will follow the re-inspection standards required by the customer and issue a full inspection report; if a concession is made, a written confirmation will be obtained from the customer. No matter which way, the defect rate data must be returned to the improvement of the production line, and no tuition fees will be paid for the next batch.
--Qihang AI Foreign Trade Research Institute·Let China Intelligent Manufacturing Set sail to the sea| Foreign trade customer consultation: 180-0327-6609
