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Quality Assurance Inspection for manufacturers

Quality Assurance Inspection

An Introduction to AQL: Check out How It Works

by Ajit Nathvani
written by Ajit Nathvani

An Introduction to AQL: Check out How It Works

What is AQL?

Acceptance Quality Limit (AQL) is an international standard for inspection sampling defined as the ‘quality level that is worst tolerable’ during product inspections. This limit refers to the percentage of defective products expected in a lot, shipment, or batch which are not detected by inspectors at specified confidence levels. Acceptance quality limits can be expressed as either a percentage or several defective items per lot.

AQL is also known as the quality level at which an inspector can accept a shipment as being within specifications. If the inspection detects more defects than what is specified in the AQL, then the entire shipment will be rejected. The purpose of using AQL is to ensure that products are not released with unacceptable levels of defects.

How is AQL Used in Practice?

AQL is used in practice to determine the number of products that can be accepted from a production run. This number is based on the percentage of defective products expected in a lot and the inspector’s confidence level in detecting these defects. For example, if a production run has a defect rate of 0.001% and the inspector’s confidence level is 95%, then the maximum number of products that can be accepted from the production run is 100.

AQL can also be used to determine whether a shipment should be inspected. In this case, the AQL is compared to the quality level of the products in the shipment. If the quality level of the products is higher than the AQL, then the shipment can be released without being inspected.

Why Use AQL?

The use of AQL helps to ensure that products are not released with unacceptable levels of defects. It also allows inspectors to set a limit on the number of defective products that can be accepted from a production run and to reduce the number of inspections. Acceptance Quality Limit (AQL) is an international standard for inspection sampling defined as the ‘quality level that is worst tolerable’ during product inspections. If you are planning to conduct product inspections, it is vital to understand how AQL works.

The Acceptance Quality Limit (AQL) table.

In Table 1 below, the intersection of the respective Lot Size and General Inspection Level indicates sample size code letter L.

An Introduction to AQL: Check out How It Works 02 The Acceptance Quality Limit AQL table.

Then, referring to Table 2, we locate row L, which indicates the required sample size of 200. To comply with AQL 2.5, no more than 10 units from that sample size may fail inspection.

3 Important Things to Understand About the AQL table.

An Introduction to AQL: Check out How It Works 03 The Acceptance Quality Limit AQL table 2

We made certain assumptions. This first was that you would use General Inspection Level II in Table 1. The second was that you would use a 2.5% AQL level for major defects and a 4.0% level for minor defects. Below we will discuss some other alternatives.

#1 What are the General Inspection Levels? (Table 1)

An Introduction to AQL: Check out How It Works 04 General Inspection Levels

There are three General Inspection Levels — I, II, and III. The level you choose is the main factor that determines how many units to inspect. In our example, we decided on Level II, which is the most common selection for general consumer products. Because of this, your sample size came out to 125 cups.

If you had chosen Level I instead, the inspector would check fewer cups, only looking at 50 of them. On the other hand, if you had chosen Level III, they would inspect more, in this case, 200 cups.

Why might you choose Level I or III?

Sometimes, inspecting fewer units (Level I) can reduce costs since the inspection takes less time. The downside is that you can have less confidence in the result. You should only conduct a Level I inspection if you have a long history and degree of trust with your supplier.

On the other hand, if you are working with a new factory or have had a spate of recent failures, you might opt to inspect additional units (Level III). An inspection with a larger sample size will take more time and effort to complete, thus costing more, but you can have more confidence in the results.

#2 What are the Special Inspection Levels? (Table 1)

An Introduction to AQL: Check out How It Works 05 Special Inspection Levels 2

There are four Special Inspection Levels — S-1, S-2, S-3, and S-4. Using the Special levels will give you a smaller sample size than any of the General levels do. For example, if you use Special Level S-1 on a 1,500-unit order, the inspector will only check 5 cups instead of the 125 from General Level II.

Why Would You Use the Special Inspection Levels?

The Special Inspection Levels do not generally apply to the entire inspection. Instead, they only apply to specific types of tests on your quality inspection checklist. For example, you might use General II to assess workmanship — checking for scratches, smudges, or cracks in the product, and you might use Special S-1 to check the dimensions of the outer carton.

  • Typically, you can use the Special Inspection Levels when:
  • Testing is destructive to your product,
  • Testing is very technical or time-consuming, or
  • Certain defects are of low concern, and you need to move quickly.

#3 What are the Various AQL Levels, Such as 1.0, 2.5, 4.0, etc.? (Table 2)

An Introduction to AQL: Check out How It Works 06 AQL Levels Such as 1.0 2.5 4.0 etc

These different levels represent the AQL percentage you have chosen for your product. Keep in mind that they represent the maximum percentage of defects you are willing to tolerate over the course of many inspections.

The typical AQL levels for regular consumer products are:

  • 5% for major defects
  • 0% for minor defects
  • 0% for critical defects

‘Major’ defects are those that will make your product unsaleable or lead to customer returns, while ‘Minor’ defects are only slight deviations from your specifications. ‘Critical’ defects are those that might pose a safety hazard to the consumer.

When working with a supplier overseas, it is important to understand Acceptance Quality Limits. AQL represents the minimum quality requirements for your product during inspections. The more you know about how it works, the better decisions you can make regarding whom to work with and what inspection levels are best suited for your needs.

For more information on AQL, please contact us at [email protected], We are more than happy to help!

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Quality Assurance Inspection

What is ‘First Article Inspection’? – How it can save entire mass production mistakes.

by Ajit Nathvani
written by Ajit Nathvani

What is ‘First Article Inspection’? – How it can save entire mass production mistakes.

You may be wondering what First Article Inspection is? First Article Inspection, or First Article Quality Control (FAQC), refers to the inspection of one of the very first pieces out of “real” mass production. FAQC is an important step for companies to make sure they have quality products before moving forward on mass production. It ensures that your good idea will be executed without any problems from start to finish of the production process.

Why are First Articles Inspected?

FAI can save your company from losing thousands – even millions! Most factory managers will not start mass production on a product unless FAQC is passed. It ensures that the first article of your product produced by the factory is acceptable and without defects or issues. This procedure helps eliminate any potential quality problems before large numbers of units are made, which saves you time and money in the long run!

When is FAI conducted?

The FAQC inspection is conducted once the factory has produced at least 100 pieces of the article. The FAI will check for issues like defamation, rough surface (if it’s a metal product), etc. This process allows finding any errors that may have occurred during mass production and correcting them right away before more pieces are made.

What happens during First Article Inspection?

Not all inspection procedures are the same, it varies for different factories or articles, but the general steps are as follows:
  • The requirements for passed FAI are clear and concise documentation. It is not a time to test the product; it should have been already tested during the pre-production sampling stage.
  • FAI inspector will check and verify that manufacturing processes are following approved drawings, specifications, and work instructions
  • Inspector also verifies that all first articles meet customer’s requirements
  • Documentation includes First Article Report (FAR) and First Article Photo Gallery
  • Final approval will be given or rejected with the reasons if FAI fails

Who should be involved?

FAI requires an extra set-up cost as well as more material. While this cost is typically borne by the supplier, it’s important to have all stakeholders – such as marketing, purchasing, quality assurance, and of course production – to make sure First Article Inspection goes smoothly. Make sure you are familiar with FAQC before your factory starts mass producing your product! There are many benefits to be had from conducting a FAQC Inspection and we’ve outlined some of the top ones below:
  • FAI provides the opportunity to fix any issues with quality before mass production begins
  • For companies, FAI helps increase consumer confidence in their product and company by ensuring that no defects exist.
  • FAI is meant for one of your very first articles made – not preproduction samples. It’s an important step to take to make sure your product is made correctly and without any errors.
  • FAI should be conducted by a team of people, including representatives from production, quality assurance, purchasing, and marketing. By having all stakeholders involved, you’re more likely to have a successful FAI.

What does First Article Inspection include?

FAI is not the same for every factory and product. It varies depending on different factories or products, but typically it includes:
  • FAI ensures that defects are kept to a minimum during mass production by testing physical dimensions of material/components
  • FAI also tests functionality – making sure the product does what it’s supposed to do
  • FAI also ensures that your products will be labeled correctly, and functionality is working before packaging begins. This includes testing whether all items are accounted for in total package number, etc.
  • FAI also includes an aging test, which is testing to see if the product will function correctly after being stored for a certain amount of time.
  • FAI typically involves checking material and components closely before mass production begins – so you can avoid any potential quality problems that could arise during production! FAI also ensures that all materials and components are accounted for before production begins.
  • FAI also tests the number of pieces per package – making sure they’re correct
  • FAI is typically completed by a team of people, including representatives from marketing, purchasing, quality assurance, and production so everyone knows what to expect!
First article inspection is an important step in the manufacturing process and should not be taken lightly. By conducting First Article Quality Control Inspections, you’re ensuring that your product is made correctly and without any errors – which can save you time and money in the long run!

What Issues does FAI catch?

  • Wrong material/component
  • Poorly positioned/loaded material/component
  • Inconsistent quality of material/component
  • Wrong processing equipment used
  • Poorly set processing equipment
  • Inability to confirm if a part is acceptable or not
  • Wrong equipment used
  • Incorrect assembly procedure that can cause problems later in the production process
  • Manufacturing issues (i.e., if any parts are missing, incorrectly oriented when assembled)
For more information on First Article Inspection or to schedule a First Article Quality Control Inspection, please contact us at [email protected] or +91 99099 46536. Remember First article inspection is a critical step in the manufacturing process and is used to ensure that no defects exist in a product before it goes into mass production.  
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Quality Assurance Inspection

5 Best Quality Assurance Inspection Practices For Manufacturers

by Ajit Nathvani
written by Ajit Nathvani

5 Best Quality Assurance Inspection Practices For Manufacturers

Manufacturers are always looking for ways to improve the quality of their products and there comes Quality Assurance Inspection Practices.  Quality Assurance Inspection Methods are nothing but the processes that ensure the product meets all requirements before it is delivered to the customer.

These practices require manufacturers to have a quality policy in place that addresses issues of quality risk, compliance with applicable regulations and development of corrective action plans.

Here are the Five Best Quality Assurance Inspection Practices

  1. Inspect all materials at the supplier’s facility:

The first Quality Assurance Inspection Practice is to inspect all materials at the supplier’s facility. This includes testing of raw material, components and sub-assemblies that are purchased by the manufacturer.  This will allow manufacturers to make sure they do not purchase any false materials, components and sub-assemblies from unreliable sources.

This also indicates that Quality Control Inspectors should report to Quality Management if any ‘rejected’ materials are purchased by the manufacturer.

  1. Conduct pre-production inspections before production begins:

The next Quality Assurance Inspection Practice is to conduct pre-production inspections before production begins. This is a quality assessment of the design and manufacturing processes that will be used to produce the product. When manufacturers conduct these pre-production inspections, they can find any faults in the manufacturing process before production begins.

This Quality Assurance Inspection Practice ensures that products are designed and manufactured with low defects rates. It also allows manufacturers to make changes if they do not meet their standards during this quality assessment.

  1. Perform in-process inspections to monitor quality during production:

Performing in-process inspections during the manufacturing process is a crucial Quality Assurance Inspection Practice. This allows manufacturers to monitor and assess products for defects or malfunctions while they are being manufactured.

Manufacturers use this practice to inspect parts, components and assemblies at different stages of production by monitoring work in the process throughout the production cycle.

  1. Conduct final inspection after production is complete and packaging has been completed:

The final Quality Assurance Inspection Practice involves conducting final inspections after production is complete and packaging has been completed. This ensures that the product’s external appearance, functionality, safety and quality meet customer expectations.

By conducting these inspections at different stages throughout the manufacturing process, manufacturers can identify any defects or malfunctions in the products before they are shipped to the customer.

  1. Provide feedback on any quality problems identified during a QA inspection with a detailed report that includes photos, videos, and samples of defective items found:

The last Quality Assurance Inspection Practice is to provide feedback on any quality problems that were identified during a QA inspection with a detailed report that includes photos, videos, and samples of defective items found. These reports should also identify the root cause of the problem and how it will be fixed, resolved or prevented in the future.

This gives manufacturers an opportunity to learn from their mistakes and prevent future quality problems.

Conclusion:

Manufacturers should use these Quality Assurance Inspection Practices to ensure that their products maintain a high-quality standard. By using these practices, manufacturers can reduce the overall costs and risks of producing and delivering poor quality products to their customers.

MV Synergy Solutions can help you and be your reliable partner for your product Quality Assurance Inspection Service. We provide Quality Assurance inspection services of various kinds, with the support and experience of our Mechanical Engineers with diverse Engineering Industry experience, who perform random dimensional inspections and prepare reports. We can also help you with certain tests and evaluation procedures using reputed agencies for Lab Testing and Non-Destructive Testing.

Contact us to learn more about Quality Assurance Inspections & Strategic Alliances.

Email: [email protected]

Phone: +91 99099 46536

 

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