Everything You Need to Know About an IPC Inspection
What is an IPC?
IPCs take place when your product is within the first 20 percent of its production phase. Inspectors use an IPC to check on the status of the product in question and assess if any defects have appeared during this early stage.
Inspectors should be referencing the internationally-recognized ANSI/ASQC Z1.4 (ISO 2859-1) statistical sampling procedure, which includes a review of your product's:
- Functionality
- Performance
- Early-stage durability
- Dimensions
- Appearance
Altogether, IPCs help you catch any issues with your production line – before they become a larger problem.
When Does Your Business Need an Initial Production Check?
To maximize the value of this inspection, you should schedule an IPC shortly after you evaluate your supply chain. This can be:
- A surprise inspection of your factory
- A scheduled inspection that is communicated to your factory
The style you choose depends on your factory and the type of insights you’re seeking.
In any case, when you perform an IPC early, you get ahead of any defects, which might otherwise go unattended.
Why are IPCs Important?
Inspectors who conduct IPCs for your business can help you:
- Lower the risk of disruption throughout your supply chain
- Double-check with your suppliers to ensure that the raw materials you receive are the best for your production
- Ensure that you can meet the quality needs of your industry
- Help you shave time off your production schedule
The sooner you conduct an IPC, the more advantages it brings to your factory. Altogether, that means:
Improved Productivity
Timeliness is essential, regardless of the industry you work in. If you can spend less time on unproductive routines, rework time and retraining, that’s more time for creating quality goods – and boosting your profits.
Fewer Bad Habits
With inspectors checking over the first 20 percent of your production line, it mitigates the chances that your factory’s staff will develop bad habits – which could save you money in the long run.
Better Adherence to Industry Standards
The management that represents your business needs to stay on top of your industry’s safety standards. Without this, you risk alienating your audience and the bulk of your supply chain. This is exceedingly difficult to do without help, as industry standards change frequently.
While an IPC is a good start, it is important to note that an IPC alone is not enough to ensure the quality of your finished products. We advise combining an IPC with a Pre Shipment Inspection (PSI) which checks your products once the full quantity has been produced. If a PSI is not carried out, you run a risk that your factory could ship bad quality products, despite your IPC.
How is an IPC Conducted?
When you request an IPC, the inspection company will send a team of inspectors into your factory.
An IPC begins with the following checks:
- Raw material quantities
- General conditions of storage
- Manufacturing process
- Production organization and status check
A standard inspection will follow, with inspectors checking the products and packaging for any defects.
The length of the inspection will vary. However, you can expect it to last about half a day, as inspectors need to watch how your factory’s employees work both on the line and while interacting with the machines.
What Does a Checklist Cover?
An IPC checklist will require you and your factory to meet quality control standards in the following areas:
- Quality and quantity of raw materials being used in production
- Compliance of the raw material composition with industry standards
- How employees set up the production line at the beginning of the day
- What accessories are used to make machines operate more efficiently
- The tools staff are allowed access to while on the production line
- The certifications gained, in order to allow work with the aforementioned tools, machines, and raw materials
- Carton drop tests
- Adhesive tests
- Hi-pot tests
- Resistance tests
Your industry may also have unique specifications that your business is required to meet. As such, IPC inspectors may bring specialized checklists.
Be sure to talk to the inspectors ahead of time; they’ll let you know if there are industry-specific quality control standards you may have overlooked or misunderstood.
QIMA and Your Next IPC Inspection
Inspectors who visit your factory want to help improve your production of goods, so they can proceed more efficiently down the supply line.
If you want to get a jump on your next IPC, how can you start?
QIMA’s team of experienced inspectors can help. When you work with QIMA inspectors, you gain access to a staff of licensed and certified quality control experts who want to help your business become even more efficient. Not only do these inspectors want to help you run a tight ship, but they can help you stay on top of production changes that may arise in your industry.
QIMA can provide you with:
- An advanced, online quality control process
- A comprehensive understanding of your supply chain and your business’s needs
- Variable pricing
- On-site inspections within 48-hours of a sent request
- Immediate inspection reports
- Speedy communication and flexibility inspection management
Ready to schedule your IPC inspection?
