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Inspection Process

What is the defect sorting service for

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After a failed pre-shipment inspection, many buyers are unsure about how to deal with the situation and what measures to take: ship, reject, negotiate, re-inspect and more. The decision depends on the defect(s) type(s) at the source of the failed inspection result. If the defect(s) are considered important by the buyer, the next questions are: Can the factory just sort out those defects? How can we make sure that they actually sorted them out?

What is the defect sorting service for?

The DSS can be used when only one or few specific defects are identified. It can be a:

  • Critical defect (dangerous to consumer)
  • General defect (a defect that affects 10% or more pieces)
  • Any defect that is unacceptable to buyer (even if found in small quantities)

There are essentially two uses for the defect sorting service:

  • To identify the gravity of a defect over the total order quantity and decide on which action to take afterwards (cancel the order, rework, reproduce 100% of the goods).
  • To sort out the acceptable and unacceptable goods based on 1/2/3 objectionable defects and to ship the adequate ones quickly. The others are staying in the factory for reworking or simply because the client won’t pay for them.

The defect sorting maximizes the number of samples to be checked for one or a few specific defects (X , Y, Z) by ignoring other defects that are acceptable in small numbers. This ensures lower cost for buyers and a better representation of the findings.

Example of what the defect sorting service is for

Let’s suppose there is an order of 4000 pairs of sneakers. A pre-shipment inspection checked 200 pairs according to AQL. The inspector found that 22 pairs had open seams, meaning that they would possibly fall apart when worn. This represents 11% of the sample size and is therefore a general defect: the inspection result is “fail” even if all of the other checkpoints are OK.

The supplier offers to rework or replace all of the defective pieces namely, those which have open seams. Once the supplier is ready, an inspector returns to the factory to check if all shoes with open seams have been replaced. There are two options:

  • Budget limitation: inspect as many pairs as possible within a specific budget (X man-days)
  • Time limitation: inspect X pairs in as little time as possible

Due to the streamlined working method of the defect sorting service, in average, 500-800 pairs can be inspected within one man-day, compared to 200-315 in a Pre Shipment (re-) inspection. This is only possible because only one defect is chosen as a focal point for the DSS, otherwise it should be maximum, a handful.

And you: what do you use the defect sorting service for?

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