Quality control China: managing QC during production

In-process production inspection, called DUPRO (during production) in the trade, takes place during manufacturing, after the start of the run and before its completion. An inspector goes to the line, randomly selects parts, and compares them to the golden sample and the specifications. The goal is not to sort the goods: it is to detect a systemic drift while it can still be corrected without stopping production.

This inspection differs from the factory's internal quality control, present in any organized factory but reporting to its management. It also differs from pre-shipment inspection, which judges the finished goods, too late to correct a cause. The former monitors the cause, the latter observes the effect: both are scheduled and complement each other.

The visit takes place after validation of the golden sample and the official start of the run, when the line is running at normal speed. Inspection firms schedule it in most cases when a limited portion of the volume is produced, roughly one-tenth to one-half: early enough to correct, late enough to judge the consistency of a run. For a first order, or with a new factory, the date is moved forward: the goal is to detect early a poorly chosen material or an unexpected subcontractor.

The date is recorded in writing in the schedule. The factory knows an inspection will occur: this already changes the workshop's vigilance.

A report is read against the specifications, not against an impression. The inspector documents, measures, photographs: he does not judge from memory.

The report quantifies the quantity produced on the day of the visit: compared to the schedule, this data tells whether the deadline holds. A deviation noted at this stage is corrected by a workshop instruction. The same deviation discovered at loading costs sorting, rework, or rejection of the goods.

Every organized export factory has an internal quality department. This inspection is necessary but not sufficient: the quality department reports to the factory management, never to the buyer. When meeting the deadline and delivering compliant goods conflict, the decision does not always favor the foreign client. An independent inspector, however, reports only to the buyer.

Three options exist. A salaried in-house inspector, which is only justified for recurring volumes with the same manufacturer. A third-party inspection firm, which charges a fixed price per man-day. Or the local team of your brokerage and sourcing firm, which combines the visit and file follow-up. This is the path we follow: an inspector who knows the file and speaks the factory's language achieves more than a standard report.

Language matters as much as independence: a workshop instruction is transmitted in Chinese, the same day, without loss.

Factory inspection is usually billed per man-day, with fees in the range of a few hundred euros depending on the production region and distance to travel. A re-inspection after corrections is billed again. Also plan for travel expenses outside the usual scope of the inspection office, if applicable.

Relative to the order value, the cost is a fraction of a percent. In contrast, non-compliant goods are resolved through sorting, rework, hastily negotiated discounts, or express freight to catch a season. The calculation is clear as soon as the order exceeds a few thousand euros.

An inspection relies on statistical sampling, defined by ISO 2859-1 and its AQL levels. It gives a probable picture of the batch, not an absolute guarantee: a rare and scattered defect can slip through. It also does not replace laboratory tests required by certain regulations, nor the CE marking to be affixed for the European market.

It does not rule on the finished goods: a batch can deviate after the inspector leaves. Solid practice therefore combines in-process inspection, then inspection before loading on ready-to-ship cartons. The first corrects the cause, the second authorizes shipment.

Sorva is a brokerage and sourcing firm active between Europe and China. Our Chinese-speaking team in Guangzhou schedules in-process inspections at your manufacturers, writes the inspection instructions based on your specifications, and follows each corrective action until verification on the line. You receive a dated report with photos and a single point of contact in Europe. The factory receives its instructions in Chinese, the same day.

In most cases, you pay no fees: you open a file, we negotiate the goods for you and take a volume commission based on the ex-works value. Our interests are aligned: a batch that drifts also costs time for our field team. Open a file with your product and schedule: we will tell you where to place each inspection and what it should check.