quality assurance Archives - ET2C International

Quality Control & Digitization

Industry Insights / admin / quality assurance, Quality Control

Quality Control & Digitization ET2C Int. QC

Quality control has always been an important part of any sourcing function. However, technology has evolved, and it is now possible to conduct inspections more efficiently and at the same time to collate data.

Overview

Quality control used to be the reserve of the ‘Policeman’; the ability to check in on factories on the basis that they were surely doing something incorrectly that would be detrimental to the quality output. As China opened up back in the early noughties, this was very much the case as offshore manufacturing (aside from Taiwan/Japan) was largely in its infancy. The anxious wait to check the QC report to see that the red coat was in fact both red and a coat. Of course, there are instances where this approach is still valid today and, in fact, recommended but often this is where the supplier relationship is fractured or there is a clear risk that needs to be addressed.

This approach has evolved over time. A collaboration is more apt to describe how quality control should sit between all stakeholders. It should be an open and fluid dialogue between the supplier and the buyer that is underpinned by trust. This means that where there are issues, they can be identified on the production line, allowing corrective measures to be implemented, rather than simply checking incorrect goods that are sitting waiting to be shipped. For example, identifying that one supplier has a high occurrence of loose threads allows this information to be relayed to the floor manager who can conduct additional training for the stitching workers. It also allows ‘quality’ to be part of an evolution of continuous improvement (in line with LEAN manufacturing principles or “Kaizen”).

factory audit check qc

Technology has a role to play as well. The ability to conduct inspections efficiently, with greater engagement between all stakeholders whilst collating data that gives direction on where any corrective measures should be focused is now possible.

Introducing Qarma

To help us continue to deliver our quality solutions to our clients, we have now partnered with Qarma going into 2022. Our aim is to empower our teams and suppliers to not just perform standardized and faster inspections via their Inspection App (the inspectors will conduct the inspections solely using their phones) but also to provide a more engaged and immersive quality experience.

QARMA QC quality control factory audit check ET2C Int.

Gone will be the two-dimensional quality control reports (and all the paper!), and in their place will ultimately be online reports and discussions. Rather than a static report, we are moving to a dynamic quality discussion to make sure that ‘quality’ continues to evolve. We are able to identify issues as early as possible and as close to the product as possible through real-time reporting and greater visibility.

Key Benefits

Some of the key benefits are set out below:

GPS Location – Every quality report can come with an exact location for each inspection
‘Fresh’ Pictures – All photos are taken and registered through Qarma with a time and GPS stamp
Barcode & QR scan – Inspectors can scan codes to start inspection and verify order
Video Capture – A picture tells a thousand words; a video tells a million (and all high resolution).
Image Annotation – Draw, write and enhance pictures with details
Multi-Language – our inspectors can explain in their own local language, which can be instantly translated across 18 different languages
Online Access – Clients can request online access and add comments and questions prior to finalizing the QC Report
Data Collation – We will automatically collate all the Quality data for your factories so that we can identify any corrective measures that need to be implemented

Quality Control 20.22

The tool will be adopted across our sourcing jurisdictions into Q1 2022 so our clients will begin seeing changes to our quality reports and the information flow. We are excited about this journey, and we just wanted to give you a heads up of what is in store for the New Year. Should you have any questions, or want to collaborate with us on Quality going forward, please contact us at contact@et2cint.com

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Factory Audit: Getting the Big Picture

Industry Insights / admin / Factory Audit, Inspection, quality assurance, Quality Control

Factory Audit Inspection Sourcing Procurement ET2C International

A Factory audit is a key component of driving visibility up your supply chain but what does it entail?

A factory audit is a necessary tool for any supply chain, particularly when you are dealing with global supply chains. Of course, you can inspect the products coming off the production line, but it is just as important to understand who you are partnering with.

Factory Audit Inspection Manufacture Sourcing ET2C Int

Whether you are considering a new supplier or you have already been working with a manufacturer for a period of time and developed a solid relationship, factory audits are essential for your business.
Managing the supply chain when it involves factories in multiple locations in different countries can be challenging. The consumer now rightly demands high standards across both the supplier and its products. On one hand, you need to therefore properly vet potential suppliers. On the other hand, you have to ensure that current suppliers have the systems in place to produce quality products. You also need to be sure that your products are free of ethical, security, or regulatory concerns.

What is a Factory Audit?

A factory audit is a type of supplier assessment that takes place at the manufacturer’s facility. This type of audit is all part of ‘Quality Assurance’ and allows companies to gain the comfort of their suppliers and any risks involved in engaging them. An auditor assesses their systems, capacity, workplace environment, or capabilities to ensure they meet your requirements. While on-site at the factory, the auditor conducts a number of checks and provides a report to aid you in your supply chain decisions.

Internal or External Audit?

Certainly, factories might tell you that they have internal audit capability and procedures that result in very low defect rates. Although this is good news (look for ISO standards for process standards that will support certain quality standards, like ISO 13485 for medical products), it remains the case that an independent pair of eyes is still beneficial as it adds a level of objectivity.

Audit Inspection Manufacture Sourcing ET2C International Procurement

Hiring a neutral third-party auditor to go to the factory gives you a more complete picture and allows you to understand where any potential risks lie. These can be around product quality, through to ethical issues such as overtime concerns for their workforce. For example, an audit could help you to:

Decide whether a particular supplier will serve as a suitable long-term partner for your needs.
Identify any financial risk or exposure should you be paying funds upfront.
Ensure that your supply chain is free of problematic social or environmental issues.

5 Common Types of Factory Audit

According to your business needs or challenges, you might consider specific types of factory audits, as follows:

1. Manufacturing Audit

This is a detailed audit on a factories manufacturing capability, and will cover workforce, production capacity, machinery through to process flows. Ultimately, these in-depth audits will determine if a supplier is capable of producing your product specifications, lead times, output, and identify any potential challenges down the line.

2. Ethical Audits

This type of audit is related to social accountability (to provide healthy, safe, and ethical work environments along with sound labour practices and pay). An ethical audit ensures the appropriate work conditions are being followed. There are a number of audits that address concerns around ethics including SA8000, SMETA and BSCI.

3. Factory Risk Report

This audit is an in-depth review of the factory that covers everything from financials, shareholding, manufacturing capability, quality management systems, product quality, ethics through to a market assessment and price benchmarking.

Factory Audit Inspection Manufacture Sourcing ET2C International

4. Environmental Audits

This type of audit helps evaluate compliance with local laws and regulations as it relates to environmental protection.

5. Customs-Trade Partnership Against Terrorism (C-TPAT) Audit

Led by the U.S. Customs and Border Protection, the C-TPAT audit focuses on improving the security, with respect to terrorism, of private companies in supply chains.

Each company has a different requirement or need at any given time. Making sure you align these needs with the different types of audit will help you have both timely information and establish the best supplier network for your business.

What is the Difference Between Factory Audits and Quality Control Inspections?

A Factory Audit plays an integral role in understanding the full manufacturing process and is distinct from simple inspections because:

1. A Factory Audit Focuses on the Long Term

While factory audits focus on the ability to meet requirements and ensure product quality is maintained, a product inspection focuses only on the products from one particular shipment.

2. A Factory Audit sees the ‘the Big Picture’.

A Factory audit covers important areas such as quality management systems and manufacturing practices. Not only they can help you assess a supplier is a good fit to produce your product but also can help you find opportunities to further develop the working relationship.

Factory Inspection Manufacture Sourcing ET2C International

3. A Factory Audit is more than ‘Product Quality’

As is clear from the different examples above, there may be many reasons to conduct a factory audit that are not just related to the product.

For more information about these differences, read our article on the difference between Quality Control and Quality Assurance.

Do you need a Factory Audit?

At ET2C we are well placed to manage your factory audit requirements. With our own dedicated quality team across Asia and Turkey, we look to deliver the visibility you need to sign off shipments. We are already investing in technology to enhance the service we provide our clients in this arena. For more information, please contact us at contact@et2cint.com.

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Quality Assurance & The “Consultants”

Industry Insights / admin / Audit, quality assurance, Quality Control

Quality Assurance Consultant ET2C Audit

Quality assurance is an integral part of ‘knowing your suppliers’ but it has to be more than just an audit trail.

Quality assurance (QA) is a way of preventing mistakes and defects in manufactured products and implementing processes to avoid further issues. It also encompasses factory audits across a broad range of areas from financial due diligence to manufacturing processes and social compliance audits. Quite rightly, retailers and brands will insist on understanding more about their suppliers to varying degrees and this visibility is an increasingly important aspect of any global supply chain. Making sure that the supplier is who they say they are, has good systems in place and is not abusing their employees is now essential information to any Buyer, and also more and more of interest to the Consumer as well.

Quality Assurance Consultant ET2C Audit Factory Check

“Guanxi” has always been a word that reverberates around discussions on China – the use of personal connections for some personal, commercial or economic gain. There is no doubt that relationships are always important in any walk of life, and this is no different in China. That said, the South China Morning Post wrote an interesting piece recently on the quality assurance industry in China and the shadowy world of ‘consultants’ who were helping factories pass factory audits through deceit and fraudulent claims.

The Consultants

The article investigates the work of independent consultants – often ex-employees of large testing houses – suggesting that there are many incidents of these intermediaries effectively forging documents and bribing inspectors to get lower end factories across the line when it comes to passing the relevant standards. Once the audit has been completed, and the factory has attained the level required, then the orders start rolling in.

Often, with yearly audit cycles, one can argue that the system is open to abuse. Also, the fact that the suppliers often must pay for the inspections themselves and they are not unannounced in the main does not help with maintaining consistent standards over an extended period – audit today, gone tomorrow (and for a further 364 days).

The Industry

It is likely that there are incidents of such behaviour. And it is clearly wrong. The intention of any retailer or large organisation buying from China would certainly not be to fund this industry or to rely on sub-standard factories. Using these factories could lead to poor quality products, which can be very costly, or Brand reputational damage should use of such a factory enter the public domain. Quality assurance is an important part of understanding the supply chain but perhaps its application and implementation is where the real issue lies.

Factory Audit Check ET2C Int

In a world in which retail is having to work harder and harder to engage with the Consumer and persuade them to buy products, different functions within large organisations are often competing for their own self-interests. Clearly, cost is commonly the weapon of choice in any negotiation when it comes to the Buyers. Driving the best commercial (low price) is still how most buying departments are judged and even rewarded. Whereas quality departments (and all the names in between) will be looking to ensure that the standards are up to their requirements. The result is an awkward marriage between commercialisation and quality assurance, which can often drive the wrong outcomes.

Quality Assurance Consultant ET2C Audit Factory Logistics

For example, the quality department will rightly say that workers must limit their working hours to 40 per week. At the same time, the buyers/merchandisers may point out that if the shipment that was placed late does not go out next week, then the factory will be charged 1% per day of the total order for each day late. At some point, there has to be a straw that breaks the camel’s back.

Conversely, if the retailers paid a little more and did not squeeze so much out of the price of a product, would they end up with sub-standard factories in the first place?

Quality Assurance

Quality assurance remains important and done correctly (regardless of some of the innate challenges mentioned above) there is no reason why there should even be this cottage industry of consultants at all. Here are some of our thoughts on how to make sure QA is working for your business:

1. ‘Own’ the Audits

This is not, and should be not, a ‘tick the box’ exercise where the inspections are outsourced accepted as presented. It requires a deep understanding of your suppliers, what makes them tick, and where the possible risks apply. The certification or standard is just the first stage, which then requires follow-up.

2. On the Ground

Having a team on the ground in any market will allow greater relationships to be developed and an understanding of the factories you partner with. This means more frequent visits to make sure they are meeting the standards (and indeed any corrective action plans as well).

3. Unannounced Visits

Always good to make sure Suppliers know auditors may turn up any time. It is always the best time to inspect a factory when they are ‘unprepared’ as it should not alter the standards in place.

4. Pay Audit Fees

When doing an external audit, to remove any leverage, it always makes sense for you to be the contracting party with the third-party auditor. Of course, if the factory agrees to pay this as part of your agreement, this can be deducted from future orders.

5. Prioritisation

Vendor identification and selection must be aligned to all functions (buying and quality). Understanding what the priority is will allow better factory selection through internal alignment.

Summary

Quality Assurance is a key part of any supply chain, wherever in the World. Make sure that you understand what the factory standards mean for your business and your consumer. The quality and buying functions are not mutually exclusive but it is important that there is alignment to drive the correct outcome.

At ET2C, we have our own inspectors on the ground, and have been helping our clients with quality assurance for the past 20 years. For more on Quality Assurance, or anything other information, please contact us at contact@et2cint.com.

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Quality Assurance vs Quality Control: a basic guide

Industry Insights / admin / quality assurance, Quality Control

Any time you outsource production overseas, it is essential to have visibility of the manufacturing process and the end product before the goods are shipped. In the same way, for any orders placed with a supplier ‘up the road’, you would make sure you were frequently visiting the site to check and oversee production (timings, raw materials etc) and importantly the product quality.
Quality control and quality assurance are two key components of any quality strategy in place. Although this is very much an evolving arena, with a shift from independent quality ‘policing’ to more of a continual improvement process through the empowerment of key stakeholders across the quality process, having an upstream capability should be the backbone of any sourcing strategy.

ET2C Insights.

We have spoken to our in-house ET2C Quality teams, who have over 20 years of experience in implementing quality processes across Asia, both internally and for our clients, and wanted to share some insights to consider with your quality strategy. We have split these across Quality Assurance and Quality Control.

Quality Assurance

1. Quality starts with the manufacturing site.

Generally, a well-maintained factory that is clean and well-organised is better placed to produce to your quality requirements. For example, if you are producing garments and the fabric rolls are kept on the floor there is clearly a greater risk of the fabric being marked or even being contaminated with mold. A good factory would have the rolls on racks, stored in a dry and clean environment.

2. Make sure you visit and walk the production process.

You should make sure that you visit any factory you are partnering with. Walk the manufacturing process to make sure that everything makes sense, from the raw material receipt, the machinery (capability), number of production lines and workers. You need to be sure that they can deliver what you need and in the timeframe too.

3. Ethical standards are important.

There are a number of certifications, like BSCI and SMETA audits, that provide a significant amount of detail when it comes to a factory’s operations and the standards and regulations that they adhere to. But, just as a little tip, watch the factory workers as you tour the factory as it can give you an insight into how happy they are in their jobs. Perhaps simply a guide, but if they are happy then it certainly points to a good work culture.

4. Partnership is Key.

As part of your quality assurance work, keep in mind that partnering is now more important than in previous years as costs rise across Asia. When we talk of ‘partnering’, we mean being fair and equitable with your suppliers. Paying that little bit more now, and perhaps committing to business over a longer period, will help you in the medium to longer-term with innovation, consistency of goods and ultimately competitive prices. With good partnerships comes trust. You will therefore be well-positioned to develop a deeper understanding of your suppliers’ operations, the risks and opportunities.

5. Corrective Action Plans.

Any supplier evaluation is likely to flag some areas for improvement. Engage with these and make sure that you understand these from the supplier’s perspective as well. What is the impact of the suggested changes, what are the challenges? How long will this take? Again, working through these with your supplier and keeping up to date will help them improve for the better.

Quality Control

1. Product Knowledge is paramount.

Whether you are using a third-party inspector or your own in-house Quality team, having an understanding of the product being inspected (inline or pre-shipment) is essential to checking it correctly. Specification sheets and gold seal samples help to facilitate knowledge transfer but where possible try to ensure consistency of the individual inspecting the goods. They will build up experience of what is and what is not acceptable and be well placed to see the product through your eyes.

2. AQL methodology is not a quality guarantee.

AQL (“acceptable quality level”) is an internationally recognised statistical sampling methodology. In short, this means that testing a random sample of a product should identify any broader quality problems against a predetermined list of major and minor defects. This is different from a piece by piece inspection which is obviously more costly. When agreeing AQL levels, make sure you are taking into account any history with the supplier, product complexity, lead times (if shortened for any reason) and value. This will help minimise the resource needed and at the same time increasing the chance of quality defects being identified and isolated.

3. Ethics in quality control.

Ethics forms an integral part of any successful independent quality control inspection. It is no secret that a quality inspector is in a position that can easily be compromised by unethical behaviour. Make sure that you listen for any noises from any parties involved factory side and, if they exist, conduct a thorough investigation to isolate and address the issue. Also be sure you have this conversation with your service provider where relevant as well.

4. Analyse the data/use technology.

Quality control is about data. Make sure you are collating it in a way that it can be analysed and manipulated. This will provide insights into not only your suppliers’ performance but also where improvements to the manufacturing process can help address the main quality defects. This continual improvement process should drive up the quality level and again reduce resource committed. The technology is already available to help manage these analytics and also drive efficiencies through the quality control piece.

5. Upstream, upstream, upstream.

Quality control needs to be conducted on-site at the factory. It means that any issues identified can be potentially addressed pre-shipment or rejected as the case may be. There is simply no point implementing a quality process that identifies issues on arrival in your own warehouse. It is too late and the cost implications (or loss) will only increase from that point onwards. You need to have some form of upstream capability.

Summary

Bad quality costs companies money; whether it is in returns, corrective measures taken, staff time on issues or simply having to discount goods to move them. It is difficult to measure at the outset before something has gone wrong and often companies therefore overlook the need to implement a sound quality strategy. This should align to your supplier markets and the products you are manufacturing. Ultimately, it is about visibility and partnership.

At ET2C we are well placed to manage your quality control and quality assurance requirements. With our own dedicated quality team across Asia, we look to deliver the visibility you need to sign off shipments. We are already investing in technology to enhance the service we provide our clients in this arena. For more information, please contact us at contact@et2cint.com.

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Quality Assurance at ET2C: Elaborate, Efficient, and Excellent

Company News / admin / quality assurance, Quality Control, sourcing

Quality Assurance is one of the biggest concerns that companies have when sourcing from Asia. Why? Over the years, a myriad of problems has occurred to entrepreneurs lacking effective communication skills when dealing with suppliers in Asian countries. Quality issues can cause the loss of hundreds of thousands of dollars or more.
These cases are not uncommon; the amount of inspection failures each year in Asia have been volatile the last few years, but still reaches high percentages.

However, there is a way to avoid becoming part of these statistics. Any company should look to ‘check before they buy’ their products. Having an upstream capability to do this in Asia is imperative to removing the additional costs once the goods arrive. Identifying issues at the factory means that they can be addressed, or worst case, they can be rejected.

Quality Assurance is an essential process in any industry hoping to ensure the well-being of their consumers.

Quality Assurance – step by step.

ET2C quality assurance processes are divided up into five different steps. Each step is an essential part of the quality control process to ensure the consistency and integrity of the product throughout all steps of production.

Raw Material Receipt

Here the raw materials of the product are laid out for our quality control agents to inspect. This ensures that from the very beginning, our suppliers are using ingredients that are conducive to your company’s specifications. This avoids many problems later in production. This step ensures that the products can handle the stresses of production, transport, or use.

Early Production Checking

After the raw materials are approved and begin the manufacturing process, they are checked once more in the early stages of production. This ensures that the right steps are being made so that any errors in production can be caught before the product continues into production, saving money and materials down the line.

In-Line Inspections

As the product moves towards the middle parts of production, it is inspected again on the production line. This is to continue to ensure the quality of the product at all stages of production. With these measures in place, it is easier and to pinpoint exactly where errors are being made.

Final Inspections

These inspections take place at the end of production and before shipment. This catches any errors in the product before they reach the customer, which make it one of the most important steps of the quality control process.

Quality Control Review, Authorization, and Release

The final step of quality control consists of condensing the information from all the inspections and the raw material receipt. First by reviewing the quality of the quality control processes, then authorizing that the information within the report is correct, and sending that information to our partners at the end. This step is extremely vital to the process. In this way, our associates can see into the course of their products’ production and are sure that their order will meet their specifications.

This can change based on a risk assessment and based on the level of engagement with the relevant factory. In fact, our aim is to implement processes that ultimately the factory can follow to facilitate a continual improvement methodology. The more eyes and processes that can be developed to eliminate defects can only be a positive development.

Quality Assurance – Our Operations Abroad

One component of quality assurance that most outsiders might not consider is how quality control is conducted in different countries. Undoubtedly, ET2C has an immersive supplier network. Because of this, we realize how to interact and ensure quality in multiple different areas of the world. Some of our biggest operating areas such as China, Vietnam, and India, vary in how quality control is viewed by suppliers.

China – trustworthy relationships and effective communication

To start with China, there are a few things for sourcing companies to keep in mind while conducting business in the middle kingdom. First, dealing with bureaucracy is a huge part of doing business in China. Because of the complex nature of government intervention in business, any manufacturing contract should be in Chinese with the specifications of the product clearly and specifically laid out and the producer company’s seal on it. This is to avoid potential legal headaches down the road. In addition, face to face conversations are absolutely crucial to producing in China. To know and to form a relationship with the supplier is a good way to ensure quality as well as effective communication of your specific production conditions.

India – the importance of independent quality assurance

ET2C’s expansive supplier network have developed the need for a comprehensive and transparent quality control process.
Next, production in India also has certain aspects that also require special attention. Like China, India has policies on quality control. Their Quality Council of India was formed to give India an edge for quality and allows for a government presence in ensuring QC. However, it is still important for a company to conduct independent quality assurance as well, since this bureaucratic arm is often stretched too thin to capture many details about the production process. This requires consistent quality management on the part of the customer, which can be done through a supply chain company like ET2C.

Vietnam – find reliable manufacturers

Vietnam, as a rising economy, is displaying many of its own unique aspects of quality control. As one of the newer developing economies, the lower cost of labor raises concerns over quality and reduced reliability. This is why it is essential to make sure that you are pairing with a reliable manufacturer. However, Vietnam has also shown itself to have a comparative advantage in producing garments, furniture and shoes. This has encouraged the government to look into methods of bureaucratic quality assurance to help encourage foreign business relationships.

Do you want to know more about quality assurance? If you have any questions or need assistance, please contact us via our website www.et2c.com

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How a Third Party Quality Control Service Can Benefit Your Business

Industry Insights, Uncategorized / admin / quality assurance, Quality Control

How a Third Party Quality Control Service Can Benefit Your Business

A third-party quality control service operates as a keystone of your supply chain. Whether you source from down the road or as far as Asia, quality control requires constant attention. When your product must meet certain requirements to sell, verifying the capabilities of your suppliers is critical.
Thankfully, quality control metrics ensure that your decision to source from Asia remains cost-effective. Through early identification of issues and swift implementation of corrective action plans, quality control services deliver sustainable value to their clients.

Why Should You Consider a Third Party Quality Control Service?

When it comes to quality control and assurance, your business should embrace the best services for your product’s needs. Quality control checks give updates for whatever steps in production you choose to inspect. Sometimes that means inspecting materials before they ship from the factory, and other times before production begins, or any number of inspections between the two.
A range of representatives operate inspections in Asia, from in-house to third party.

How a 3rd Party Quality Control Service Can Benefit Your Business list — Third party quality control services ease bias concerns.

With an In-House Inspector at the Factory

In-house inspectors work from within the factory, developing quality control reports at requested moments in production. If you have established the trustworthiness of a factory, then this option is certainly viable. With a continuous improvement methodology and training at the factory level, it is possible to move to a self-certification inspection process that puts the responsibility for quality inspections firmly on the Supplier.

However, there is a potential conflict of interest. Loyalty may warrant that their interests align with the manufacturer over their clients and a costly mistake on the factory floor may be pawned off as certified for importers to discover in their own warehouses.

With a third Party Quality Control Service

Third-party quality control services function as the industry standard for quality control. They are objective and have experience across different product categories, which provides additional added value when it comes to potential product-specific quality issues.
Control parameters play an invaluable role in the performance of quality products. There is little doubt as to the value of a third party quality control service in Asia.

What Quality Controls Do I Need for My Business?

Early audits of factory and supplier capabilities ensure that your partners are capable of fulfilling orders. At this point in the process, you should be examining the methods and metrics of quality control. Manufacturers must demonstrate the infrastructure and technology necessary to identify and correct any errors in production.
Visibility is paramount. Understanding the production process and the materials being used to make your product are key to a successful production. It is important to recognize potential communication issues stemming from your instructions. Every part of your product specification creates a measurable benchmark for a third party quality control service to validate. Once you define a key metric, quality control checks evaluate whether production is meeting those expectations.

Some metrics are already set, like the Acceptable Quality Limits (AQL) outlined in the ISO 2859-1. While your own expectation can aim higher, meeting these baseline expectations can critically impact the salability of your product.
Critically identifying potential issues upstream, on-site, at the factory will remove significant future cost. Once the products have been shipped costs have already been incurred and it is likely that the cost of goods has already been transferred to the supplier. Getting anything back at that stage is problematic at best. Therefore, investing in third party quality control services has a significant benefit to your business and provides a level of comfort that your company’s money is being well spent.

How a 3rd Party Quality Control Service Can Benefit Your Business — Guide your product through the supply chain with peace of mind regarding quality.

Transparency and Accountability

Finding a trustworthy third party quality control service will provide a significant benefit to your business. We at ET2C International understand the necessity for transparency and accountability because they are core to what we do each day.
Contact us to learn more about the role of a third party quality control service plays in your supply chain and the range of services that we can provide.

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How Important Is Quality Control Service for Your Business?

Industry Insights / admin / manufacturing, quality assurance, Quality Control, sourcing

A quality control service enables cost-efficient, Asian sourcing with transparency and accountability. If you source from any location that you do not directly oversee, quality control checks and a quality assurance capability are an absolute must.

When your supply chain operates a few thousand miles away, popping into the factory for necessary inspections is rarely a realistic option. But, distance should not lead to a drop in product quality.

Overseas Should Not Mean Oversights

Sourcing from overseas countries introduces a range of new risk factors to an already complex manufacturing process and supply chain. Proper sourcing solutions and active management alleviate these factors to maximize cost-effective quality.

Quality control services act as a filter between each step of your manufacturing process. One common misconception businesses encounter when they seek quality assurance is the idea that such services eliminate all risk.

A quality control service cannot guarantee that nothing will go wrong. Rather, their job is to identify issues early to help determine the best quality solutions. Quality control specialists conduct most final inspections under internationally recognized sampling methodology (AQL). Rather than checking every single piece, inspectors sample shipments for errors.

Strategic sourcing identifies issues early — A professional quality control service can mitigate how costly a mistake becomes.

Why Do You Need Quality Control Services?

At this point, you may find one question running through your mind: If they cannot prevent all possible mistakes, then why bother hiring a quality control service?

Issues will occur and problems will manifest themselves. Quality control services provide the capability to manage these upstream. Once a Quality control specialists identifies an issue, quick implementation of correction action plans ensures that quality products still ship in good time.

When is the worst time to discover a quality problem? Whilst standing in your warehouse staring at the open container. Quality control plays an integral role in preventing such a scenario.

Identifying problems early in the manufacturing process empowers businesses to modify or, if necessary, reject the product upstream (on factory site) to eliminate the additional costs of shipping unsalable goods.

Quality Control Service Bottle Source — Early detection can prevent issues from rippling through production.

When Should You Perform Quality Control Checks?

Depending on your product and history with your supplier, you may choose any combination of the following inspections. Products which carry higher risk factors at certain stages in the process may require more attention.

Hiring a professional quality control service also ensures that audit-level tracking documents record each step of the process.

One of the most important standards is the Acceptable Quality Limit (AQL). The AQL is defined in the ISO 2859-1 as “The quality level that is the worst tolerable.” It is based on a sampling methodology that should identify any quality issues. Over the course of several inspections, AQL testing demonstrates your products’ compliance to industry standards.

1. Raw Materials at the Factory

Low quality materials rarely make high quality products. Raw material receipts secure a baseline for the foundation of your product, particularly when your product must meet government regulations and customer expectations.

If poor raw materials are used, then they will likely impact the appearance, function or chemical composition. This means that for certain product types, if the raw material is not correct, you will not get the product required at the end of the production line. This can be a particular type of yarn in a garment or the type of wood to build furniture. In terms of time and financial risk, raw material inspections can save entire productions from getting reduced to scrap.

It is also a useful check to confirm that lead times any supplier has already committed to are on time.

2. Early Stages of Production

Once goods reach the production line, early product checking inspections can begin. If manufacturers drill holes too wide or cut corners at the wrong angle, early identification is key. This should be based on a risk assessment on the supplier (history, relationship etc) and the type of product manufactured. To an extent, this also focuses on the manufacturing process as well to understand where the potential risks lie.

Like a dress rehearsal, early stage inspections distinguish immediate concerns. Corrections should be adjusted as quickly as possible to maximize the usability of remaining materials.

3. Middle Line Inspections (During Production – “DUPRO”)

Once production is significantly underway, in-line inspections assure that everything still aligns to specifications. Sort inspections may be necessary at this point in the process if inspections identify issues.

4. Pre-Shipment Inspection (PSI)

After production, but before packaging for shipment, inspections of products ensure that you receive products which meet your initial specifications. Typically conducted using AQL, PSI relies on the sampling based on the production volume against the agreed inspection standard. Before incurring the cost of shipping, it is vital to validate your product. PSI represents the last opportunity to accept or reject factory manufacturing before shipping the goods.

How Important Is Quality Control Service — Reduce costs by preventing shipments of unsalable goods.

5. Loading Containers (Loading Inspections – “LI”)

Oversight in packaging specifications can lead to factory-primed goods arriving damaged beyond recovery. Ensuring proper loading of pallets and boxes increases the likelihood of the goods surviving any shipment on the sea. Container seal numbers are commonly provided at this stage to maintain the integrity of the shipment from port to warehouse.

6. Sort Inspections (Any Stage)

If an issue arises at any point in production, sort inspections may come into play. They establish an exact count of which products are affected and which are not.

Sort inspections isolate impacted units and remove them from the process. Only products without the defect move forward.

Which Inspections Does my Business Need?

The best combination of inspections depends on both the supplier and the products’ risk factors. Fragile products, or those which must meet high standards for sale, require more attention throughout their production. Some companies may not offer the inspections best suited to your business’s needs.

Quality control services not only conduct these inspections, but are responsible for compiling data and relaying it to their clients. It is important to discuss how often such information is shared and during which points in production.

Our experienced team at ET2C International is here to service your quality control needs. Transparency and accountability drive us to continually improve our inspection communications capabilities.

How Important Is Quality Control Service for Your Business? Read More »

QUALITY matters more in 2016 than ever before.

Industry Insights / admin / et2c, procurement, quality, quality assurance, sourcing, trading

Consumer demands are more relevant.

Consumers know that they have the power to make demands of their favorite brands and products; this power resides in consumers’ ability to take their opinion to the Internet and have it spread like wildfire. The rest of the world will know their love or hate of a product, and we’ve all see the force of a negative review.

This has created a faster response rate in companies. In some cases, not complying with the consumers’ demands will result in losing not one, but thousands of customers in a short period of time. Saving money on quality will most likely cost your company more in the long run.

As consumers are shopping more and more online, quality is almost always the most important factor in a product review. Why is this relevant? A recent Nielsen study found that 70 percent of global consumers trust online reviews; this has risen by 15 percent within a four-year period. Industry experts project this trend to further increase in the coming years.

Five product evolution questions you should constantly be asking your team:

How good is the current quality of my product compared to 5-10 years ago?  You might have had the coolest, best performing, and innovative product of 2007… But what does that mean today? And more importantly, what will that mean five years from now?

Should we be using the same materials? As products evolve, raw materials, new compounds and 3D printing prototypes have become real options to explore.

Could we improve product design? If you’ve reached product perfection (we highly doubt it), skip this one.

Can my current supplier manage upgrades? Once you’ve made up your mind where you want to take your product, it’s time to check if your current supplier is the right one to execute those changes.

5.Are my products sustainable? As we become more environmentally conscious, this becomes a bigger issue in people’s minds and their purchasing decisions.

If there are no metrics to measure, there is no way to improve…

When it comes to production, if your company is just scratching the surface of the problem, then the developing product strategy will most likely have a short term range. If you want to implement a more long term strategy, where decisions make an actual impact on your quality, then you HAVE to measure data.

Developing, testing, and the goods and the bads…all need to be measured.  By analyzing past production data, it’s easier for your planning team to predict and forecast future sales with a higher accuracy, thereby obtaining a higher ROI.   

Quality is remembered long after price is forgotten

One way of ensuring your quality standards is to always aim for the re-buy. Put yourself in the shoes of the consumer and review your product experience – from the moment they engage with your product to the moment they need to replace it. You will then have a transparent idea of what you need to improve and change. This is a great way to ensure that your products will go beyond your clients’ expectations and come back for more.   

“Quality isn’t something that can be argued into an article or promised into it. It must be put there. If it isn’t there, not even the finest sales task will save you.

Quality Measuring Quality

We listened to our clients’ needs and created the ET2C Quality Control APP.
We deliver your reports in real time with photos. Additionally, there’s the digital signature from the supplier and the GPS location of the inspection, all through our APP installed in our inspectors’ tablets.

Our QC rate is only $190 USD per man day, send a message to amy.h@et2cint.com and book your inspection right now!

QUALITY matters more in 2016 than ever before. Read More »

What is a Factory Audit?

Internal or External Audit?

5 Common Types of Factory Audit

1. Manufacturing Audit

2. Ethical Audits

3. Factory Risk Report

4. Environmental Audits

5. Customs-Trade Partnership Against Terrorism (C-TPAT) Audit

What is the Difference Between Factory Audits and Quality Control Inspections?

1. A Factory Audit Focuses on the Long Term

2. A Factory Audit sees the ‘the Big Picture’.

3. A Factory Audit is more than ‘Product Quality’

Do you need a Factory Audit?

The Consultants

The Industry

Quality Assurance

1. ‘Own’ the Audits

2. On the Ground

3. Unannounced Visits

4. Pay Audit Fees

5. Prioritisation

Summary

ET2C Insights.

Quality Assurance

1. Quality starts with the manufacturing site.

2. Make sure you visit and walk the production process.

3. Ethical standards are important.

4. Partnership is Key.

5. Corrective Action Plans.

Quality Control

1. Product Knowledge is paramount.

2. AQL methodology is not a quality guarantee.

3. Ethics in quality control.

4. Analyse the data/use technology.

5. Upstream, upstream, upstream.

Summary

Quality Assurance – step by step.

Raw Material Receipt

Early Production Checking

In-Line Inspections

Final Inspections

Quality Control Review, Authorization, and Release

Quality Assurance – Our Operations Abroad

China – trustworthy relationships and effective communication

India – the importance of independent quality assurance

Vietnam – find reliable manufacturers

How a Third Party Quality Control Service Can Benefit Your Business

Why Should You Consider a Third Party Quality Control Service?

With an In-House Inspector at the Factory

With a third Party Quality Control Service

What Quality Controls Do I Need for My Business?

Transparency and Accountability

Overseas Should Not Mean Oversights

Why Do You Need Quality Control Services?

When Should You Perform Quality Control Checks?

1. Raw Materials at the Factory

2. Early Stages of Production

3. Middle Line Inspections (During Production – “DUPRO”)

4. Pre-Shipment Inspection (PSI)

5. Loading Containers (Loading Inspections – “LI”)

6. Sort Inspections (Any Stage)

Which Inspections Does my Business Need?

Five product evolution questions you should constantly be asking your team:

If there are no metrics to measure, there is no way to improve…

Quality is remembered long after price is forgotten

Quality Measuring Quality

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