Factory Quality Inspection Guide: Pre-Shipment Inspection (PSI)
- Conduct PSI when the order is 100% produced and at least 80% packed into export cartons.
- Adopt the ISO 2859-1 (ANSI/ASQ Z1.4) Acceptance Quality Limit (AQL) standard, typically General Inspection Level II.
- Categorize defects strictly into Critical (0 allowed), Major (typically 2.5 AQL), and Minor (typically 4.0 AQL).
- Tie final balance payments (usually 70%) contractually to an official "PASSED" inspection certificate.
- Draft an Inspection Protocol detailing product specs, function checks, and packaging requirements.
- Book a third-party inspector (e.g. QIMA, V-Trust, AsiaInspection) at least 5 business days before the scheduled ex-factory date.
- Ensure the inspection mandate includes carton drop tests, barcode checks, and electrical safety tests.
- Do not release wire transfer until reviewing the full photographic inspection report.
| Defect Class | AQL Standard | Definition | Examples |
|---|---|---|---|
| Critical Defect | 0.0 (Zero Tolerance) | Poses safety hazard or fails legal compliance | Exposed electrical wiring, sharp edges on toys, mold |
| Major Defect | 2.5 AQL | Impairs product functionality or causes customer returns | Unit fails to power on, cracked enclosure, wrong logo |
| Minor Defect | 4.0 AQL | Cosmetic imperfection not affecting core function | Minor paint smudge, slight carton scuff, loose packaging tape |
The False Economy of Skipping Inspection
A comprehensive one-man-day inspection by a professional agency in coastal China costs approximately $250 to $320. In contrast, discovering a 15% defect rate after an ocean container arrives in Los Angeles or Rotterdam incurs thousands of dollars in unsellable stock, return shipping, and Amazon account health demerits.
Inspection should be budgeted as a mandatory operational cost, not an optional insurance policy.
Protocols When an Inspection Fails
If the inspection result is "FAILED" due to excessive defects, do not panic. Do not release payment. Issue a formal remediation notice requiring the factory to 100% sort, rework, and replace defective units at their own expense.
The factory must also pay the cost of the re-inspection once rework is complete, as established in your purchase agreement.
Frequently Asked Questions
Can I trust factory self-inspection reports (QC pass)?
No. Factory internal QC answers to factory management whose priority is shipping orders on time. Always use an independent third-party inspection agency.