Quality Control Services in Malaysia

Quality Solutions Overview

Click on the current stage of your sourcing or product development journey below to explore our related quality solutions.

1. New Product Development

2. Supplier Selection

3. Supplier Qualification

4. Pre-Production Validation

5. Production Planning

6. Incoming Quality Control

7. Production and Assembly

8. Outgoing QC & Shipping

Development & Planning

Production & Delivery

1. New Product Development

New product development lays the foundation for strategic sourcing. Prototyping is crucial to validate that the supplier understands the client’s requirements.

Pro QC inspections validate the new parts while our supplier development services align quality expectations with suppliers and strengthen their ability to meet quality requirements and reduce time to market.

Pro QC’s Quality Solutions:

First Article Inspection (FAI)
Supplier Development Services
Resident Supplier Quality Resourcing

Supplier Risks & Challenges:

Poor communication of technical details between buyers and factories
Misalignment of product specifications and critical design requirements among buyers, suppliers, and factory production teams
Inadequate consideration of advanced product quality planning
Challenges when transitioning from prototype suppliers to mass-manufacturing suppliers
Misalignment on design and engineering revisions

2. Supplier Selection

Once the component specifications are defined, the procurement department identifies a list of suitable suppliers that can potentially meet their capability, cost, capacity, and quality requirements.

Pro QC offers a range of supplier due diligence and supplier evaluation support. Our experts visit suppliers to assess their capabilities, mitigate the risk of scams, overpromises, and miscommunication, and validate their credentials, trustworthiness, and financial stability.

Pro QC’s Quality Solutions:

Supplier Quality Audits
QHSE Audits
ESG Audits
Onsite Supplier Verification
Financial Credit Check

Supplier Risks & Challenges:

Lack of experience and due diligence in new supplier region
Communication challenges
Concern about supplier scams
Low confidence supplier’s trustworthiness
Concerns over supplier’s financial viability

3. Supplier Qualification

A world-class organization usually has a comprehensive supplier qualification program to identify and mitigate the risks associated with quality, safety, on-time delivery, cost, and compliance.

Pro QC establishes a global audit program to systematically onboard new suppliers, categorize their risk levels, and establish a reaction plan based on the supplier’s performance on quality systems, environmental management, and social and ethical compliance.

Pro QC’s Quality Solutions:

Global Supplier Audit Programs
Supplier Quality Audit for Potential Suppliers
Quality Management System Audit
Social & Ethical Audits
Supply Chain Security Audit
Environmental Audit

Supplier Risks & Challenges:

Suppliers are not as capable as they initially claimed
Supplier lacks effective and systematic quality assurance practice
Supplier is ISO 9001 certified, but the underlying principles are not implemented in practice
Mass production quality does not match prototype quality
Buyers want to sell to big retailers, but their suppliers do not yet comply with the retailer’s supplier code of conduct
Supplier violation on labor law, ethical and environmental compliances
Goods held in customs due to supply chain security malpractice

4. Pre-Production Validation

Before commencing volume production, it is crucial to validate that the equipment, staffing, production methods, capacity, and quality control plan are in place for each product line.

Pro QC offers on-site quality support to prevent and reduce the potential cost of poor quality (COPQ) and risk, ensuring a smooth transition from product development to mass production.

Pro QC’s Quality Solutions:

Engineering Build (EB) and Quality Build (QB) Audit
First Article Inspection (FAI)
APQP/PPAP Audit
Manufacturing Process Audit or VDA 6.3 Process Audit
Resident Supplier Quality Resourcing

Supplier Risks & Challenges:

Factory not ready for mass production
Shipment delays due to critical failure, poor quality, and resource constraints
An exponential increase in defective products
Product recall
High Cost of Poor Quality
An exponential increase in the cost of change after mass production commences

5. Production Planning

Production planning ensures that the supplier has sufficient raw materials, components, and staff and that other outsourced processes meet the specified schedule.

Pro QC offers assistance in timely supplier communication, onsite visits, and daily or weekly monitoring reports. This minimizes the risks of delays from ineffective procurement planning, staff shortages, or sub-supplier mismanagement.

Pro QC’s Quality Solutions:

Order Expediting
Resident Supplier Quality Resourcing

Supplier Risks & Challenges:

Production delay due to poor material procurement planning
Production delay due to inadequate production staffing
Poor sub-supplier management

6. Incoming Quality Control

Incoming inspection reflects a factory's commitment to quality control from the outset. Understanding how a factory manages its incoming material and its supply chain is a very good indication of its commitment to quality.

Pro QC quality solutions address issues such as defect acceptance, material substitutions, and component decay due to poor practices or storage conditions.

Pro QC’s Quality Solutions:

Incoming Inspection
In-Process Inspection
Manufacturing Process Audit or VDA 6.3 Process Audit

Supplier Risks & Challenges:

The factory does not manage the quality of its supply chain or is poor at supplier management
Suppliers turn a blind eye to defective components during incoming and still use them for production and assembly
Using sub-standard material or components (e.g., lower-quality fabric than required)
Substituting lower-cost alternatives for product components (e.g., cheaper electronic components in a mobile phone)
“Quality fade” where suppliers make small, gradual substitutions in materials and components over time
Bulk material ordered by the supplier degrades over time due to poor storage conditions

7. Production & Assembly

Many things can go wrong during mass production due to machine failure, lack of process control, and operator mistakes. While it is normal for defects to occur, these defects must be detected and contained.

Pro QC offers a range of support to verify control plan adherence, early defect detection, quality improvement, and issue resolution through monitoring, investigations, and CAPA validation.

Pro QC’s Quality Solutions:

First Article Inspection (FAI)
In-Process Inspection
Manufacturing Process Improvement
Quality/Root Cause Investigation (8D)
CAPA Verification
Order Expediting
End-Of-Line Testing & inspection
Resident Supplier Quality Resourcing

Supplier Risks & Challenges:

Operators are not producing according to the production control plan
Supplier is under pressure to ship goods, turning a blind eye to defective components
Lack of quality staff to enforce quality control
Poor control of re-worked material/product
Mistakes made by temporary, untrained staff/operators
Communication breakdown when the supplier is under pressure

8. Outgoing QC & Shipping

The smallest aesthetic defect on the packaging or missing components can lead to customer returns, while a misplaced label may result in compliance issues. Outgoing Quality Control is the last line of defense before products are properly loaded into containers for shipment.

Pro QC offers pre-shipment inspections and end-of-line testing to ensure your products meet your quality requirements and reduce the chance of returns or re-work.

Pro QC’s Quality Solutions:

Manufacturing Process Audit
Poka-Yoke Implementation
Pre-Shipment Inspection
End-Of-Line Testing & inspection
Container Loading Supervision
C-TPAT Audit

Supplier Risks & Challenges:

Products are poorly packaged
Human mistakes and missing components lead to customer returns
Wrong labeling leads to compliance issues and significant re-work
Rough handling of goods during container loading by the factory or outsourced warehouse, leading to damaged product
Poor container loading leads to product damage during transit

Product Inspection in Malaysia

Product inspections are a good quality control tool to ensure that the product’s appearance, functionality and other criteria follows your requirements. Pro QC International offers rework, sorting and product inspections in Malaysia at various stages of the production process to assess the quality of the goods. Our local quality control experts in Malaysia are highly trained and experienced with a variety of consumer and industrial products such as hand tools, furniture, textiles, electronics, automotive parts, mechanical parts, metal products, medical products and more.

Our product inspection services in Malaysia include:

First Article Inspection

Prior to the start of mass production, our local quality engineers verify that the engineering of the product -drawings, parts, functions and other specific requirements- conform to your specifications. This process ensures that specifications are well understood, verified and documented.

In-Process or In-line Inspection

An in-process inspection allows us to detect errors that might lead to a non-conforming product before production is completed. Quality engineers verify that the manufacturing processes are reliable and consistent, and that the products coming off the production line meet the strictest requirements.

Pre-Shipment Inspection

Performing pre-shipment inspections in Malaysia helps reduce the risk associated with receiving defective products before shipping the goods. Our quality control inspectors provide detailed feedback and images to document any non-conformity as part of our comprehensive inspection reports.

During pre-shipment inspections in Malaysia, our quality engineer generally employs metrics such as ANSI Z1.4 sampling plans to evaluate workmanship, functionality, packaging, labeling, and other criteria as required.

Pro QC reviews and checks against existing client specifications but we can also assist in the development of criteria if desired. Our QC engineers generally use Pro QC’s standard report forms of which we would be happy to provide you with samples. We can also use checklists or report formats provided by clients. Reports including images will always be available online within 24 hours of completion of the service.

Container Loading Supervision

At the end of the supply chain, we offer container loading supervision at the factory or major ports to ensure safe transportation and delivery of the goods to their final destination. This inspection service supervises the loading process and involves monitoring the quantity of the packed goods, checking the storage and condition of the container before and after closing it, and whether the goods are correctly handled/placed into the shipping containers.

Major ports where we can conduct container loading inspection services in Malaysia include:

• Port Klang
• Penang Port
• Johor Port

Product Sorting & Rework Services in Malaysia

Pro QC International offers comprehensive sorting and rework services in Malaysia to ensure product quality and compliance with standards. These services include identifying and sorting defective products and conducting rework activities as needed. The process involves visual inspections, dimensional inspections, and functional testing to meet client requirements. Pro QC caters to various industries globally, providing tailored quality solutions to improve product standards, reduce scrap, and maintain customer satisfaction. In Malaysia, our product sorting services cater to a wide range of product categories including automotive parts, mechanical products, medical devices, textiles, furniture, plastic products, and more.

Welding Inspection

We provide welding inspections in Malaysia. Our solutions include verifying the quality of welded products through various methods such as document review, witness inspections, visual and dimensional inspections, and non-destructive testing. Our skilled welding inspectors ensure weld quality conforms to industry standards and client requirements. Pro QC operates in various fields, including industrial equipment, oil & gas, transportation, and more.

Coating Inspection

We assist our clients in ensuring the durability and integrity of coatings, which protect against environmental elements like corrosion and weathering, through our comprehensive coating inspection solutions. Pro QC’s comprehensive approach includes document review, pre-coating, in-process, and post-coating inspections.

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Supplier Management Services

Pro QC’s Supplier Management solutions have been developed to resolve quality defects and non-compliance. The first step of the service is a gap analysis based on the relevant industrial standard to identify the root cause of the quality issues and create a tailored solution to resolve the quality shortcomings. For example, we reduce defect rates, improve your factory performance, and support our clients to prepare for certifications or comply with international standards (IATF 16949, VDA 6.3, ISO 9001, ISO 45001, and ISO 14001).

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