Quality control is more than just a checkbox on our operational list at Ardencraft Technology; it is the cornerstone of our operations. The assurance of impeccable product quality is not only a commitment but a responsibility we wholeheartedly embrace. To translate this commitment into tangible results, we have engineered a rigorous quality control process, with the Final Quality Control (FQC) being the crowning jewel of our quality assurance efforts.
What is AQL?
AQL, or Acceptance Quality Limit, is a widely adopted statistical sampling method used in quality control. It provides a structured way to determine the acceptable quality level of a product by specifying the number of defective items permissible in a given lot size.
How are Lot Sizes Selected from AQL?
Lot sizes are selected based on the AQL table, which outlines acceptable and non-acceptable quality levels depending on the number of defects found in a given sample size. Lot sizes are typically determined by considering factors such as order quantity, industry standards, and the criticality of product defects.
AQL Table:
Critical Defects: 0 allowable defects
Major Defects: Up to 2.5 allowable defects
Minor Defects: Up to 4.0 allowable defects
The Significance of the FQC (Final Quality Control) Process
The FQC (Final Quality Control) process is the sentinel of product quality, safeguarding the integrity of our operations. It represents the final safeguard of our quality control journey, designed to leave no stone unturned in verifying that each product adheres to its unique quality standards.
Let's embark on a journey through the core components of our FQC (Final Quality Control) inspection process:
Final Inspection: What is FQC and Why is it Important?
The FQC (Final Quality Control) process serves a twofold purpose: first, to ensure that the product's quality meets manufacturing standards, and second, to intercept and rectify any production-related issues promptly. The significance of this phase is immense, as it contributes to saving time, resources, and the product itself.
In essence, final inspection acts as the "quality police" at the production stage, preventing any deviations from quality standards that may cascade into larger issues down the line.
Outgoing Quality Inspection: Final Quality Control Assurance
Before our products embark on their journey to reach our clients, they undergo an exhaustive outgoing quality inspection. This terminal checkpoint is the last safety net, meticulously designed to ensure that the products departing our warehouse are flawless.
In addition to standard FQC procedures, we asked the factory for their functional test data that was carried out on all of the products. We cross-reference the data against the specification and take x10 random units to carry out functional tests of our own. It means - all the products are tested before shipping and we can verify the integrity of the test data by carrying it out ourselves. If any steps are missing, or products fail basic functional tests - then the factory has skipped key steps. We would prevent this batch from shipping from the factory until a full investigation is carried out by the factory.
You don't want your customers to receive "brand-new" goods that do not function as expected.
Our mission is crystal clear: zero defects. Outgoing quality inspection stands as the final guardian, certifying that the products are impeccable and ready to meet the high expectations of our clients.
How is FQC Selected?
FQC (Final Quality Control) selection is based on AQL (Acceptance Quality Limit) tables, which set the standards for checking manufactured product quality. Here's how it works:
Determine Sampling Plan: AQL tables provide a structured sampling plan that dictates how many units from a production lot should be inspected and tested. The sampling plan is usually based on three key factors:
AQL Level: This is the acceptable quality level, which represents the maximum allowable percentage of defects or non-conformities.
Lot Size: The total number of products in the production lot.
Sampling Level: This refers to the number of units to be inspected from the lot, which varies based on the criticality of the product and the AQL level chosen.
Random Sampling: Using the parameters established in the AQL standards, a random sample of units is selected from the production lot. The randomness of the selection is essential to ensure that the sample accurately represents the entire lot.
Conduct Quality Inspections: The selected units are thoroughly inspected or tested to check for defects, non-conformities, or deviations from the specified quality standards. The type and depth of inspection can vary based on the product and its quality requirements.
Evaluate Results: After the inspections are completed, the results are evaluated against the AQL standards. This involves comparing the number of defects found in the sample to the AQL limits. If the number of defects falls within the acceptable range defined by the AQL, the batch is considered acceptable for release. If the defects exceed the AQL limits, the batch may be subject to further action, such as rework or rejection.
The use of AQL tables in FQC helps strike a balance between ensuring product quality and not subjecting the manufacturer to excessive testing and inspection costs. It provides a statistically sound method for making accept/reject decisions based on a representative sample from the production lot. The specific AQL and sampling levels chosen can be tailored to the product's quality requirements and the manufacturer's quality control strategy.
A Practical Glimpse into a Real FQC Inspection
Let's get practical and look at a genuine FQC inspection to get a better understanding of how this process works:
Unpacking the Inspection Details
Product Name(s) & Reference(s): ArdenPower Banks
Service No.: 230922C41
Supplier Name: X Factory
Service Location: Shenzhen, Guangdong, China
Order Quantity: 5000 pcs
Sample Size: 80 pcs
What the Report Reveals
The inspection, conducted with meticulous attention to detail, unravelled several facets of the product. Here's an in-depth look at the findings:
Production Status: Passed
100% of the ordered quantity was found to be finished and fully packed, promising timely deliveries.
Export Packing: Hold
This area highlighted concerns about packaging and factory support for a drop test.
Shipping marks, gross weight, and dimensions exhibited minor deviations, calling for an adjustment to meet client specifications.
Inner Packing & Labeling: Hold
Some discrepancies were noted in the dimensions of the instruction manual.
The absence of zone labels raised concerns about traceability.
Product: Hold
Several products exhibited blue LED displays, which may not align with the desired product appearance.
There was insufficient time for proper charging and ageing tests.
The factory's inability to conduct high and low-temperature tests adds a layer of complexity to the quality evaluation process.
Number of Defects vs. AQL: Failed
The most striking revelation was the number of defects that surpassed the AQL limits. These defects included scratch marks, discolouration, tool marks, and issues with LED displays.
Taking a Closer Look
Let's explore a few key areas in more detail:
Production Status Details:
This section demonstrated that the production had been completed to a satisfactory level, giving assurance that orders could be met.
Export Packing:
Minor discrepancies in the packaging aspects remind us of the need for precise adherence to client specifications.
Inner Packing & Labeling:
Misaligned dimensions and the absence of zone labels underscore the importance of meticulous attention to detail in inner packing.
Product:
The unexpected appearance of blue LED displays on some units suggests variations in product quality.
The constraints in conducting comprehensive tests, including high and low-temperature assessments, leave room for quality improvements.
Number of Defects vs. AQL:
Exceeding AQL limits for defects implies the need for an enhanced quality control process.
These issues are typically related to manufacturing and quality control problems:
Tooling Marks: These are often seen in metalworking or plastic moulding processes. Tooling marks can appear as scratches, dents, or other surface imperfections caused by the manufacturing equipment.
Scratch Marks: Scratches can occur on various products, from electronics with delicate screens to glass or metal surfaces during handling or production. They can affect the aesthetics and functionality of the product.
Glue Marks: When adhesive is used in manufacturing or packaging, glue marks can be an issue if they are visible, uneven, or excessive. This is common in the assembly of electronics, paper products, and various consumer goods.
Colouring Issues: Color discrepancies are common in industries that rely on precise colouration, such as textiles, printing, and automotive. This can include variations in colour, colour fading, or mismatched components in an assembly.
Damage to Packaging: Damaged packaging can be a significant problem in industries where packaging serves both a functional and aesthetic purpose. This includes torn labels, crushed boxes, or packaging with visible wear and tear.
Conclusion: Your Assurance of Quality
The Ardencraft FQC process acts as the last safeguard against poor quality. We do not waver in our commitment to quality; these reports are evidence of our dedication to that cause.
However, it's important to remember that while inspection reports are crucial for communicating findings, they should not replace product liability insurance or be considered evidence of shipment. Instead, these reports provide you with the assurance you need to make informed decisions about your sourcing requirements.
For a deeper conversation about our processes, how we can serve your unique needs or any additional information, our dedicated team is at your service. We invite you to explore the world of global sourcing with a partner you can trust, Ardencraft Technology.
For further insights and detailed information, please don't hesitate to visit our website: Ardencraft.