Tag: aql

What types of defects occur most often during inspections?

Over the last three decades, we have inspected an innumerable amount of orders for clients looking to mitigate sourcing risk and uncertainty. As a result, one question we receive often regards identifying trends or commonalties among defects noted. We asked two of our key team members in Ningbo, China what the most commonly noted issues during inspections include: “Workmanship is the most common issue due to the variation.”  ~Cynthia Liu (Business Team Manager) “Inconsistency in production.” ~Nick Chen (Technical Supervisor) Although each product is unique, we are able to classify our observations by general industry. During inspections, defects are generally classified …

3 Ways to Use Defect Data to Drive Improvement

Our quality engineers collect data from supplier locations all over the world, and we encourage our clients to get as much value as possible from our reporting to drive overall improvements and support successful supplier partnerships. Consider the simplified example of conducting weekly pre-shipment inspections of one product at a single supplier site.  The information provided in the product specification determines the defects and whether they are major, minor or critical, which the quality engineer checks for on-site when evaluating the random samples.  An accept, reject or on-hold determination is made for each inspection based on the AQLs and other …

The sampling app you’ve always wanted… ANSI Z1.4 2003 made easy

Pro QC’s team of technical engineers has developed an Android and iOS application that takes the guesswork out of the accept or reject determination of an on-site quality inspection depending on customizable major and minor AQLs (Acceptable Quality Limits). This application has been incredibly useful for our team on-site, in addition to many of our clients. For convenience, we also have a web-based application. More on defect classifications here. To learn more about ANSI Z1.4 2003 sampling, a previous article discusses the topic in more detail.

Which AQL do you choose?

One of the most frequent questions we receive regarding on-site quality inspections relates to selecting AQLs, or Acceptable Quality Levels.  AQLs represent the maximum percent defective that you consider acceptable. Pro QC’s Assistant Operations Manager in China, Cesar Marsical, address the question below: The selection of AQLs and sampling plan for a given lot size depends on too many factors to permit the issuance of a “pre-selected” standard set of plans for specified lots. Each user should select AQLs and sampling plans that are tailored to best meet their needs.  Pro QC can assist with this process. Some of the …

Evaluating inspection reports

Many companies anxiously await product quality inspection results and focus on the “accept” or “reject” status alone.  However, it is important to note that useful information exists within the details that are worth examining.  Here are a few things that should be considered: Defect Trends – An accepted inspection doesn’t mean that no defects were noted.  It just means they fell within the AQL (Acceptable Quality Limit).  Maintaining a spreadsheet of defect data can help identify trends and areas of improvement.  Using the idea of 80/20 (Pareto), continuous improvement efforts can be targeted at defects contributing 20% of the total, with the …