Quality Assurance refers to systematic procedures in the manufacturing process that ensure a high quality end product.
Unlike other inspection companies RediSource does not just report errors and defective products. We take a hands-on approach and implement preventative measures in the initial phases of production to mitigate time-consuming errors that often result in defective goods.
We can also assist in negotiations with factory personnel to fix errors and work closely with the factory to avoid costly errors in future runs. And, with RediLink™ you can easily customize criteria and tolerances, access evaluation reports, and revise inspection dates, and receive important updates right from your desk.
We have six inspection offices in mainland China: YiWu, Donguang, Shenzhen, Ningbo, Chaozhou and Guangzhou, which oversees inspections for the entire China coastal region. We also have an office in Bangkok, Thailand that handles inspections in all regions of the country.
Acceptable Quality Limit (AQL)
RediSource uses the international standard called Acceptable Quality Limit (ANSI/ASQC Z1.4/ MIL-STD-105E), which was developed during World War II by the U.S. Department of Defense and applied to everything from artillery to boots. AQL is a statistical analysis that determines the number of items to be inspected and the objective line between what’s acceptable and what’s not for defective products.
AQL and Random Sampling Size
Depending on usage, functionality and customer expectations, each produced item will require varying sampling sizes. In general, the more variation an item has, such as hand-made goods, the larger the sample size needed to ensure that you have an adequate representation of the variances. Similarly, items with little variation, such as manufacturing components, require smaller sample sizes. View the AQL Sampling Chart.
AQL and Defects
In addition to setting the sample size, you need to determine the acceptable level of defects that an item can have in order to pass an inspection. Defects are normally measured on a scale of critical, major, and minor levels of irregularity.
- Critical level: Any defect that results in an inoperable and/or unsafe product
- Major level: Any defect that reduces the function, usability, appearance, and/or the
ability to sell the product
- Minor level: Any defect that diverges from the original product definition
Example: A manufacturer that produces 20,000 mechanical watches requires a General Inspection Level II, which means 315 watches will be inspected at random.
Critical level = 0
Any critical defect signals a failed inspection | Example: Non-functioning watch
Major level = 2.5
14 or more major defects signal a failed inspection | Example: Inaccurate time
Minor level = 4.0
21 or more minor defects signal a failed inspection | Example: Wristband scratch
Manufactured goods often adhere to standard AQL settings and defect criteria. However, with RediInspect, we work with you and your team to gain an in-depth understanding of how your product works to create custom definitions for acceptance level criteria.
RediAdvantage Inspection Services
This is a comprehensive formal document created at the start of the manufacturing process to inform the supplier(s) of the client-approved criteria and standards for the intended product in terms of size, functionality and aesthetics.
Criteria reports are created in the native languages of all factory personnel and we ensure that the production manager uses the guidelines outlined in the document to implement exacting internal quality controls for product specification targets. This report has proven that it can prevent a significant number of costly production errors and keep production schedule on track.
Supplier Verification Inspection
A short version of the Factory Audit, this is a 1-day audit that verifies the supplier and provides basic details on factory operations, as well as answers important questions, such as: Is the factory a trading company? What type of license does the business have? Does the factory have access to the required equipment or are is it outsourcing?
RediSource can complete a Sample Check as part of our Sample Management services or as a stand-alone service where we conduct a series of quality checks for samples either in before or after production begins.
RediSource can provide a full-spectrum analysis of finished tools with our readily available Coordinate Measuring Machine (CMM), and we can run a First Article Analysis (FAI) on your tooling and evaluate specific parts. We can also conduct Process Capability (Cp, Cpk) or Process Performance (PP, Ppk) analyses depending on the life-cycle of your moulding toolings.
A preferred service at RediSource, we conduct an unannounced inspection at a factory in the event there is a pattern of miscommunication and delays with a supplier and/or factory. By viewing the factory operations first-hand, we can often quickly arrive the source of the problem and determine the best course of action.
Standard Inspection Services
First Batch Inspection
We conduct an inspection on the initial day of production to ensure all goods adhere to client-approved standards and criteria, to verify that the supplier and/or factory is employing the correct components, and to test and certify raw materials.
A production inspection is commonly required upon 30% to 40% completion of a production run to ensure the quality of goods.
We conduct a 2-day inspection of a factory and present a full-account of its capabilities, including machining and production capabilities, and relevant licenses and certifications.
Using the AQL (S1, S2, S3, S4, I, II, III and 105E (MIL-STD-105E) standard, we work with you to set the appropriate AQL for your goods and and then inspect all products based on this criteria.
Container Loading Inspection
In order to ensure that your products are property shipped and contain no broken cartons or products, RediSource conducts an inspection both before the vendor or factory is ready to load final products into a container and during the loading process.
This inspection checks the quantity of items, container conditions, load process, product packaging and packing. We can also inspect a selected sampling size of your products as a final check for workmanship and primary functionality.