A European motorcycle accessories brand contacted us regarding its motorcycle helmet production in Taiwan. They needed quality control solutions to ensure that the products met their agreed specifications with the Taiwanese supplier before shipment to Europe. Having experienced quality challenges with their current supplier—and with their operations based in Europe—they lacked the internal resources to conduct on-site inspections due to time constraints and the high cost of deploying their own team. As a result, they opted to work with a third-party quality control company. They chose Pro QC because of our established office in Taipei, our ISO 9001 certification, and our ability to deploy highly qualified inspectors with expertise in their fields cost-effectively. After an in-depth meeting with an account manager and the development of a customized solution, the client selected Pro QC for this critical project. The Solution Motorcycle helmets are vital safety devices, especially for riders, as they are among the few products designed to protect users during accidents. Ensuring helmet quality was paramount for our client, who was committed to the safety of its customers. Although the client had previously produced helmets with the same supplier, recurring quality defects in earlier production runs necessitated additional support for this new production cycle. In their communications with us, the client provided comprehensive details regarding product specifications, packaging, and the history of defects. Leveraging our extensive industry experience, we developed an inspection plan that included both In-Process Inspections and Pre-Shipment Inspections. Pro QC produced customized inspection reports tailored to the product and the client’s specific situation. In-Process Inspection Our In-Process Inspection commenced at the very start of the assembly line. This evaluation covered: Assembly Process Verification: Inspectors reviewed the manufacturing assembly process, ensuring that all Standard Operating Procedures (SOP), Standard Inspection Procedures (SIP), and Work-In-Progress (WIP) documents were accurately followed. QA/QC System Implementation: We verified that the factory’s quality assurance and quality control systems were properly implemented at every stage of the production line, ensuring consistency and adherence to the agreed specifications. Pre-Shipment Inspection In the final phase, our Pre-Shipment Inspection scrutinized the finished helmets before they were shipped out. This final check was crucial to confirm that the products met all quality requirements and were ready for export. It included: Packaging and Labeling Verification: Inspectors confirmed that both the inner and outer packaging were intact and complied with the established specifications. All labels were checked for accuracy, proper placement, and clarity to ensure traceability and compliance with market standards. Final Weight and Dimension Checks: The gross and net weights of the helmets were precisely measured to guarantee they matched the agreed specifications. Dimensional assessments were also performed to detect any deviations that could potentially lead to compliance issues or impact user safety. Visual Evaluation: A detailed examination of the helmet’s surface was conducted to identify any cosmetic defects, such as scratches, dents, or irregularities in finish. This step also involved a sensory evaluation where applicable, ensuring that the overall appearance met the high-quality standards expected by our client. Documentation and Compliance Review: All relevant documentation, including quality test reports, certificates, and compliance records, was meticulously verified to ensure that the helmets conformed to both international and local safety regulations. Final Condition Assessment: Beyond individual checks, a comprehensive review of each finished product was conducted to identify and document any non-conformities. This allowed for immediate corrective actions before shipment, reducing the risk of delivery issues and reinforcing customer trust. These extended pre-shipment inspections ensured that every helmet leaving the production facility was safe, compliant, and met the highest quality standards required for successful market entry. Results & Benefits Pro QC’s intervention allowed the client to identify critical quality defects before shipment to Europe, thereby preventing the receipt of substandard products that could have led to costly product returns, rework, or damage to the brand’s reputation. Notable findings included: In-Process Inspection Findings: Incomplete Process Documentation: The in-process inspection revealed a lack of detailed documentation for the assembly processes. Essential procedures—such as the use of cleaning agents and adhesives, screw torque monitoring and management systems, soldering iron temperature ranges and operating times, as well as the location, dosage of hot-melt adhesive, and lubricating oil specifications—were missing or insufficiently defined. Packaging Label Issues: The inspection identified that carton and pallet labels did not conform to the required standards. Pre-Shipment Inspection Findings: Reiterated Labeling Error: The typographical mistake on the labeling was again observed during the final inspection. Certification Issues: The necessary ABS MTC/MTR certification was not provided by the factory. Dimensional Discrepancy: Dimensional Discrepancy: A key measurement was 12mm rather than the specified 20mm, a significant deviation that could lead to compliance issues in the EU market and potentially compromise user safety. Thanks to these comprehensive inspections, the client obtained reliable and impartial information regarding production quality. This allowed them to work with the supplier to implement corrective actions, ensuring that only products meeting the specified requirements were shipped to Europe. Extended Collaboration Following the successful resolution of these issues, the client extended its collaboration with Pro QC to include inspections in Vietnam and China, where Pro QC also maintains a strong presence. This continued partnership underscores the value of independent, thorough quality control in maintaining high product standards across multiple markets. Key Takeaways Challenge: ensuring product quality without a presence on the ground Solution: In-Process Inspections and Pre-Shipment Inspections Products: helmets Location: Taiwan Outcomes: improved quality and customer satisfaction About Us Pro QC International is a global quality assurance company with over 40 years of experience in quality. Our range of quality control solutions includes quality inspections, factory audits and supplier management services. Contact us for more information, or to request a quote.
