Inspector Growth Guide (2)

3.3 Preparation work before inspection

If a worker wants to do his job well, he must first sharpen his tools.

No matter which industry we are determined to work in or what work we do, preparation before work is crucial to our success or failure. Therefore, before we plan to inspect the goods, inspection preparation is very important to us, and it can even determine the success or failure of our inspection work that day.

My suggestion is: the day before departure, make a draft of your work process for the next day in a notebook, and rehearse the next day's work in advance. This will help you organize it. ideas, predict some emergencies, think of countermeasures, and prevent omissions.

In my previous job, I once met a QC, and I asked him to help me go to a factory in Shantou for product inspection. The day before departure, I called him and asked him to contact the factory to confirm the inspection date, factory address, and the completion status of the goods to avoid missing out on the trip.

After he listened to what I said, he said: "You mean to let me contact the factory now to see if the goods are ready?

If not, then there is no need to go. ? "

I said: "Yes. "

Then he said to me: "I am the QC, and I am going to inspect the goods. If the factory does not do it well, I still have to go. You care? I just go to the factory and check if there is any. If you want me to confirm it in advance, you should go find someone else. I won't go. "

That seems right. , as QC, we will inspect the goods when they are in stock and come back if they are out of stock. But he forgot that whether as a QC or in other positions, the company asks you to do things because it hopes everyone can see the problem from the company's perspective. If after arriving at the factory, the factory says that the inspection date has been changed, or that the inspection is at their branch factory, can these unnecessary troubles be avoided? Think about it. In the end, you went to the factory, failed to inspect the goods, and then returned the same way. Do I need to pay you? If I pay you, will the company still seek cooperation with you in the future? If they don’t pay you, would you still want to cooperate with this company in the future? This has happened to us before.

Our peers, no matter what position you are in, if you can position yourself higher and look further ahead. Approaching work with an owner's mentality will get you far.

Let’s get down to business, let’s take a look at a table first:

Table 1: QC pre-inspection inspection table

3.4 Inspection Operation Guide

The following is the general process of inspection. Of course, it is not static. Many processes can be carried out in order of each other. If you feel that it is convenient and suitable for you, then boldly make corresponding changes according to your own preferences.

The basic inspection process is as follows:

Arrive at the factory -> Meet the factory representative -> Briefly introduce the inspection arrangements -> Warehouse points -> Warehouse extraction - 〉Sample boxes are transported to the inspection room——〉Unpacking and sampling——〉Product inspection——〉Defective product labeling——〉Defective product record——〉Defective product photography——〉Product/packaging photography——〉Inspection results and Introduction to defective products -> Factory written confirmation of inspection results

Below I will post a rough inspection process (in English). You can feel it and test your English level. If you read If you don’t understand, then you can give it a try according to the method we mentioned above.

1. Receive allocation email from the Supervisor

2. Check the inspection information in the email (As soon as possible)

2.1. Check the order, packing list, approve sample, delivery time, etc.

2.2. Look for the missing information

2.3. Immediately call or send email to Supervisor if have any problem

< p> 3. Prepare inspection checking list (Day before inspection)

3.1. Call factory to confirm the inspection time

3.2. Inspection order, Specification, shipping mark, packing list etc.

3.3. AQL based sampling inputs

3.4. Freelancer inspection procedure,

3.5. Draft inspection report form,

4. Inspection day

4.1. Go by bus or train to the factory (keep receipts)

4.2. Meet the contact person in factory

4.3. Take picture of gate , building, and office

4.4. Visit the production lines and take pictures

4.5. Check out if the production is ready for FRI (at least 80% packed,

and the 20% remaining in the

packing stage)

4.6. If production not ready:

4.6.1. If production soon ready ( less than 2 hours), wait in the factory

4.6.2. If production ready in a long time (more than 2 hours), call the

supervisor and ask the factory to

sign on the Missed Inspection notice

4.7. If production ready, perform inspection:

4.7.1. If necessary change AQL inputs

< p> 4.7.2. Take picture of the whole lot (all cartons)

4.7.

3. Randomly pick up the number of cartons required by AQL tables

(square root of lot size) and

record selected cartons numbers.

4.7.4 . Take pictures of chosen cartons

4.7.5. Check out all the shipping marks: front, side, inner

4.7.6. Take pictures of all shipping marks

4.7.7. Record the designation number of the chosen cartons

4.7.8. Take a few pieces to check measurements, colors, materials

4.7.9. Take the samples in each carton

4.7.10. Inspect samples carefully

4.7.11. Put aside the defectives, with arrow stickers near defects

4.7.12. After the whole sample has been inspected, focus on defectives and

categorize the defects (critical,

major, minor), and review all defectives with representative of the supplier or factory

4.7.13. Sum up each type of defect (Several defects in one piece is counted

as one defect, the more

important)

4.7.14. Fill up the draft report, and have it signed by the factory

contact

4.7.15. Take pictures on each defect (MUST BE CLEAR)

4.7.16. Complete the draft report, please fax to company office if

available in factory.

4.7.17. Go back to the office or home as soon as possible

4.7.18. Upload pictures into computer

4.7.19. Work them out

4.7.20. Input the draft report in the official report< /p>

4.7.21. If too far from the office or can't go back the same day, then

fax the Draf

t report to office, and

send the pictures by email (Find an Internet connection)

5. Pictures Requirements:

Pictures should include the followings as many as possible:

- Gate of factory

- Buildings of factory

- Production lines

- Inspection room or sample room

p>

- All outer cartons

- Cartons selected for inspection

- Individual product (per color)

- Individual packing

< p> - Inner packing

- Outer packing

- All labels / marks on product, inner and outer carton

- All defect samples (per defective style) MUST BE VERY CLEAR

- Front mark on cartons

- Side mark on cartons

- All relevant tests performed during inspection

- etc..

Rename all pictures first, then use Photoshop software or ACDsee resize

on 320 X 240 pixel

size, if you have a lot of picture you can compress the folder before

sending it to us by

"win-zip" or "win -rar"

How about it, is it verified? Do you have a general understanding of the cargo process?

Next, we will introduce the key control points and operational suggestions of each step in detail starting from the warehouse counting step to ensure that our inspection results can represent the true quality level of the inspection batch to the greatest extent.

3.4.1) Warehouse counting

The counting process mainly involves going to the site to count the number of boxes and the total number to confirm the completion status of the product and the authenticity of its completion status. This ensures:

·The completed production quantity can satisfy a large enough sample number, thereby restoring the true quality level of the inspection batch to the maximum extent

·The authenticity of the completion status of the production product, through This ensures that after passing the inspection, the factory can ship the goods in time

· Minimize the factory to relax the quality control of the last few products after receiving the qualified inspection report, thereby causing the proportion of unqualified products to be excessive. Big hidden dangers

Main cases seen:

·The factory did not complete the specified order quantity, but in order to meet the customer's inspection arrangements, empty boxes were placed in the middle of the cargo pile to fill the quantity.

·The factory did not complete the specified order quantity, and the unit failed to meet the customer's inspection arrangements, so the inspector was asked to overwrite the product quantity. When the customer finally wanted to arrange shipment, the factory said that 50% of the goods were not completed and could not be shipped, which resulted in economic losses.

·The inspector only counted the total number, but not the quantity of each model and color. In the end, there were more products of some models or colors, but less products of other models and colors.

·The quality of the inspected products is very good, but the quality of the bulk goods exported to customers is very poor

Suggestions:

·Point counting and sampling Pay attention to whether there are empty boxes

·As inspectors, we must always remind ourselves of the responsibilities and professional ethics of inspectors. We cannot lose a lot with a little. As the managers of the inspectors, we can ask the inspectors to take pictures of the entire cargo pile when taking photos, and how many boxes there are can be seen from the pictures. This operation is done to avoid false reporting of quantities as much as possible.

·As inspectors, we must try our best to confirm the quantity according to product style/color. We have to make sure that our work is organized, especially when there are orders with many styles and colors, we don't get confused by ourselves.

Example: I once asked an inspector to help me go to Cixi to inspect the goods and supervise the loading. After inspecting the goods and loading them into cabinets, he himself did not know how many quantities of each model had been completed and how many had not yet been completed. In the end, I had to call the factory to ask. Isn’t it very frustrating? His main problem was that he only counted the total number but not the quantity of each item. In the end, some styles were packed with more colors, while others were packed with less, and the boxes were still in the factory. In the end, we had to arrange express delivery abroad.

·The quality of the products during inspection is good, but the quality of the bulk goods exported is very poor. The possible reason is that a small part of the product is made, and then the goods are inspected. After the inspection passes, the factory relaxes quality control, so the quality of the final goods is relatively poor. Of course, there are other reasons for this, as you will see in subsequent chapters of this book.

3.4.2) Warehouse box picking

The process of box picking in the warehouse is mainly to ensure that the samples taken are random and can restore the true quality level of the inspection batch to the greatest extent .

Past cases:

·I don’t know how many boxes were picked, resulting in a too small proportion of boxes

·The boxes were too concentrated in a certain area or a certain batch number. A certain production date, resulting in a non-representative sample

·There is no aisle in the factory goods pile, and the boxes on the inside cannot be drawn, resulting in a non-representative sample

·After the boxes are drawn, The factory did not draw the boxes according to the number drawn by QC

Suggestions:

·The number of boxes to be drawn is based on the root number of the total number of boxes. For example, if there are 100 boxes and the root number is drawn, then 10 boxes will be drawn.

I once did a quality system audit for a large home textile group in Beilun, Ningbo. I won’t mention the name of the factory. Because the factory’s sampling method could not be seen on the factory’s product inspection report, I asked the factory’s quality manager how they determined the number of boxes to be sampled.

She replied: "We sample according to the inspection quantity on the AQL sampling form. If the total number of products is 10,000, we will sample 200."

I will ask again. She: "How many cartons did you draw 200 samples from?"

She said a little angrily: "We draw enough 200 samples according to AQL. Why do you always ask me to draw 200 samples according to the box?" . The implication is that do you understand sampling?

In this example, she ignores the problem of sample box size and only captures the number of samples. Let’s take a more detailed example: Assume that the total number of sample batches is 10,000, each box contains 100 products, and there are a total of 100 boxes. According to ISO2859, ordinary level II sampling plan, the number of samples is 200, and each box contains 100 products. For products, if we only sample 200 samples, are two boxes enough?

Then someone asked, what should I do if the total number of boxes is less than 10 boxes? For example, if there are 9 boxes, is it still a root number? In this case, my personal suggestion is to smoke it all. All items under 10 boxes are available.

·When drawing boxes, we can reasonably allocate the boxes according to the box number segment. For example: if there are 100 boxes in a box, then there will be 1 box in the 1-10 box section, 1 box in the 10-20 box section, and so on. If there are any last-numbered boxes, it is recommended that the last-numbered boxes must be drawn.

Similarly, we can also reasonably allocate (if applicable) our sampling plan by date code, batch number, and production workshop.

·In practice, we have encountered some factories that deliberately stack goods without leaving aisles, so that you cannot extract the innermost products. So what should we do? There is no shortcut. The factory can only move the goods pile to extract the goods inside. This is done because: firstly, we have the responsibility to ensure the randomness and representativeness of the sampling; secondly: there are always a very small number of factories that use this low-level method to pile defective products inside. To avoid inspection, some factories even put some empty boxes in the innermost part of the goods pile to achieve the purpose of filling up the quantity.

·When picking out boxes, we’d better write down the box numbers of the boxes we picked out in our own books, sign or mark the boxes we picked out, and then ask the factory to help remove the boxes from the pile. Pull it out. The purpose of this is to make it easier for you to know whether the factory has pulled the goods out of the goods pile according to the boxes you picked; secondly, some customers require that the number of the boxes picked be written on the report. If they are employees with a little experience, they will write down the box numbers they sampled to review the rationality of their sampling. Another advantage of writing the box number on the report is that when a customer complains about a product problem, it is convenient for you to trace whether the product in question belongs to the box you sampled.

·When picking out boxes, it is best for the QC inspector to pick out one box, and the factory takes out one box from the goods pile and puts it on the other side. Some factories will deliberately slow down the process and wait for you to finish all the boxes before taking you back to the inspection room. After you leave the warehouse, let the factory workers slowly smoke, or even directly replace the goods in the box you smoked with A-grade products that have been fully inspected by factory QC. I did this kind of thing in the first factory I worked in.

·When the same model in the inspected batch is packaged separately in different colors, the boxes should be sampled according to the proportion of each color in the total number. That is to say, different colors and different models should be sampled in the same proportion according to their proportion of quantity. This is a bit like the congressional seats in the United States. The proportion of members of each state in the Congress is always consistent with the proportion of that state's population to the total population of the United States.

3.4.3 Transport sample boxes to the inspection room

Purpose:

Make sure that the sample boxes transported to the inspection room are the ones you picked, and The box was not dropped midway and was replaced.

Past cases:

·Boxes were exchanged during transportation

Suggestions:

·After unpacking, accompany the factory throughout the entire process to transport the sample boxes Go to the inspection room.

·Sign on the sealing tape on the front and bottom of the sampled box to prevent it from being opened by the factory

To be continued