Quality inspections in manufacturing reduce costs by cutting waste from defective products and decreasing the amount of labor required to fix faulty components. They also help to ensure compliance with regulatory requirements and build a strong, resilient business.
Performing regular quality inspections can minimize communication issues regarding production timelines, shipping dates, and quality expectations between manufacturers and their suppliers. There are three main types of quality inspections in manufacturing:
Pre-production Inspection
This phase involves checking the quality of raw materials before production begins. Specifically, inspectors examine the consistency of the material’s various parameters such as size, shape, weight, color, odor, and moisture content. Furthermore, they verify whether the quantity of the raw material meets production requirements. Since 80% of a product’s cost comes from materials, confirming their availability becomes a top priority in this inspection.
Besides examining the quality of raw materials, inspectors also check supporting components crucial to mass production, such as machinery and equipment. They cross-check each machine to confirm precision and ensure sufficient quantities for the assembly line. As a result, manufacturers can rely on the equipment to produce high-quality products in a timely manner.
Manufacturers must keep in mind that finding faults at the final stage of production is more expensive than doing so earlier. The so-called “1:10:100 ratio” illustrates how the costs escalate the later a fault is found in a finished product. Therefore, optimizing pre-production inspections is a vital step in reducing costs and improving product quality.
During this phase, inspectors evaluate the factory environment, taking photos and studying site reports. This is important because the environment must support a standardized production process, creating high-quality products without endangering workers. Additionally, the factory must have a good relationship with its suppliers.
After the inspection, a comprehensive report is compiled. It outlines all the findings of the inspection, including supplementary site photographs and videos. This allows manufacturers, stakeholders, and regulatory bodies to gain a clear and comprehensive understanding of the inspected aspects.
In addition to ensuring quality standards, a PPI can also save resources for other projects by reducing rework and avoiding the need to travel to Asia to work with suppliers on fixing issues. This can reduce production delays and improve time-to-market while also maximizing return on investment. In addition, a PPI can also help businesses improve transparency with suppliers. This can increase trust and encourage more positive business relationships, leading to better quality and performance. It also helps buyers build a stronger reputation and brand image by delivering quality products that meet their customers’ expectations.
In-process Inspection
According to Asia Testing & Inspection, creating norms and requirements for the quality inspection process is important in order to maintain consistency throughout the manufacturing process. The standards must also be communicated to employees and managers, so that they can ensure the quality of work is maintained. This will prevent problems from occurring at later stages of the production process and ensure that the final products meet the stated quality standards and criteria.
During the inspection, the inspector should take note of any deviations and make corrections as needed. This will help to reduce the amount of time that is spent on inspection, which in turn can increase worker productivity. Using an inspection checklist that has been specifically designed for the business will ensure that all the relevant details are covered and that no step is skipped. It is also a good idea to periodically review the inspection checklist, as it may need to be updated due to new industry norms or changing equipment.
Another way to improve efficiency and accuracy is to use a quality inspection software solution that integrates with MES or ERP systems. This will automatically collect and report on inspection data. It will also enable the automation of scheduling, routings, and work instructions, as well as escalations. This will further enhance productivity and reduce human errors. In addition, implementing visual elements like annotations, drawings, and labels in the inspection process will help to clarify the steps involved and increase the effectiveness of the process.
In addition to reducing costs, a quality inspection system can also boost employee morale and create a sense of ownership in the company. This will lead to better product quality, which in turn will result in greater customer satisfaction and loyalty. Moreover, the quality inspection system will also help the business to maximize resource utilization by controlling waste and low standard production.
In today’s environment of downsized staff, it is essential that manufacturers focus on in-process inspection to ensure that all products are being made properly. This will also allow them to avoid last-minute delays and avert wasting material. Inspecting the goods after they are finished is too late, as many issues can be missed during this stage – from poor packaging to bad glue and even the dreaded excuse, “it must have appeared during transportation”. By focusing on in-process inspections, businesses will be able to deliver better products to their customers and maintain their reputation.
Post-production Inspection
Inspecting the final product before shipping is a crucial step. It’s the last chance to catch defects that may have developed during manufacturing or in storage (e.g. mold, glue that has dried, etc). It’s also an opportunity to verify that all quality standards have been met.
Identifying problems early on saves money. Manufacturers don’t have to waste time and resources fixing the problem, which can be expensive and lead to production delays. It prevents costly returns and replacements, and it helps manufacturers maintain high quality standards and customer satisfaction.
Many manufacturers chafe at the idea of paying for quality inspections, but those who have experienced issues such as product recalls, scrapping or reworking products, and accepting costly return customers come to see inspections as a cost-effective investment that saves time and money in the long run.
Inspections at each stage of production can help ensure that the end result will be what you and your customers expect. They can also save you the cost of rework, returns, or lost business.
Manufacturers can implement a variety of inspection procedures to meet their specific needs. Regardless of the type of inspection, a proper sampling plan should be followed to make the inspection as accurate and efficient as possible. Having the right tools to automate visual checks is vital, especially when it comes to inspecting the smallest details of complex assemblies.
In addition to implementing a quality inspection system, you need to establish clear and consistent expectations for your suppliers. This will ensure that everyone understands the standard acceptable quality limits for your products and prevent pushback when you receive goods that fall outside of these standards.
Whether you’re buying raw materials, finished products, or assembled components, it’s important to have a comprehensive inspection process in place to reduce your risk. An effective inspection system will help you maintain quality production standards, meet regulatory requirements, and foster procurement processes that positively impact supplier accountability. Quality inspections are the most effective way to mitigate risks, and a thorough inspection strategy will ensure that your customers’ experience is positive from start to finish.
Equipment Inspection
A well-designed inspection program ensures that equipment can keep up with the demands of the production process. This reduces the risk of equipment malfunction and downtime, which can lead to costly delays and production disruptions.
It also prevents expensive workers’ compensation claims and other legal costs that result from equipment failures. In addition, it demonstrates a strong commitment to following strict safety requirements and demonstrating due diligence and compliance with industry regulations.
Most heavy machinery is designed to work hard and endure harsh conditions, but this can also mean that it will break down at some point. Regular inspections allow for the identification of recurring issues and the timely repair or replacement of the equipment, which will minimize maintenance costs in the long run.
Keeping the equipment in optimal condition is also essential to improving productivity and ensuring that projects are completed on schedule and to specification. Unplanned downtime can significantly impact the profitability of a business and may even force the company to hire additional employees to cover the lost workload.
Manufacturers often need to inspect a variety of different equipment, and they can divide this machinery into categories based on its criticality to the production process. Indispensable equipment – which could cause the whole production to grind to a halt if it fails – should receive the highest priority and attention, while marginal machines can be inspected less frequently.
Inspections are a key part of any quality control system in manufacturing and have many benefits for companies, including improved efficiency, reduced production costs, consistent product quality, increased brand loyalty and customer satisfaction, and better safety for employees and customers. Effective engineering inspections can help manufacturers avoid costly product defects, which can have a detrimental effect on the reputation of their products and brands. Regular inspections also help to identify issues early in the production process, which can minimize rework and waste later on. This is one of the most important benefits that inspections have for manufacturers.
