10 Essential Tips For During Production Inspection

By Author: TIC
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In the high-stakes world of global sourcing and manufacturing, quality is not a feature—it’s the foundation of your brand. Waiting until the final product is boxed up to discover a critical defect is a nightmare scenario that leads to costly reworks, delayed shipments, and damaged customer trust. This is where the During Production Inspection (DPI) steps in as your brand's shield, transforming quality control from a final check into a continuous assurance process.

Also known as an In-Process or DUPRO inspection, a DPI typically takes place when 10% to 20% of your order is complete. It is the most critical checkpoint for catching systemic issues before they spiral out of control.

At The Inspection Company, we see the difference a proactive DPI strategy makes every single day. Here are our 10 Essential Tips for a Highly Effective During Production Inspection.

1. Define the "Acceptable" Before Production Starts

The single most common flaw we see is an undefined quality standard. Your inspectors—whether in-house or third-party—must have a crystal-clear benchmark.

The Tip: Create a comprehensive ...
... quality control checklist (QCCL) before the first material is cut. This document must go beyond simple aesthetics. It should include:

✅ AQL (Acceptable Quality Limit) levels for major and minor defects.

✅ Critical dimensions and tolerances.

✅ Specific material/component details (color codes, weight, texture).

✅ Required on-site function tests (e.g., stress test, drop test, electrical test).

Why it matters for DPI: If the inspector can objectively measure a semi-finished product against a fixed standard, they can stop non-compliance immediately.

2. Schedule the DPI at the "Point of No Return"

Timing is everything in a DPI. You want to inspect enough finished goods to get a statistically valid sample, but you also need to leave enough time to implement corrections without causing a major delay.

The Tip: Target the inspection for when the first major, non-reversible process is complete, or when 10% to 20% of the total quantity is finished. This is often after assembly but before final finishing touches like special coatings, permanent printing, or inner-packaging.

Why it matters for DPI: If a core structural defect is found at 80% completion, you have to scrap 80% of your order. Finding it at 20% completion means a much smaller, manageable loss.

3. Prioritize Critical Defects and Systemic Errors

A DPI is not just about finding single, isolated defects; it's about uncovering the root cause of recurring problems. The inspector’s focus must shift from a 'product check' to a 'process check.'

The Tip: Instruct your inspector to prioritize:

✅ Defects that affect safety or primary function (the Critical Defects).

✅ Defects that appear across multiple inspected units, indicating a flaw in the mold, a machine setting, or a faulty component batch.

✅ Incorrect components or materials being used mid-stream.

Why it matters for DPI: Correcting a recurring issue (a systemic error) at the source prevents thousands of future defects.

4. Verify All Raw Materials and Components

The quality of the final product is only as good as the raw materials that go into it. While a Pre Production Inspection (PPI) is ideal, the DPI provides a second chance to verify what’s actually being used.

The Tip: Have the inspector physically check a sample of the raw materials currently on the production floor against your approved specifications, including:

✅ Material certificates (if required).

✅ Color, texture, and feel against approved samples.

✅ Correct supplier markings on outsourced components.

Why it matters for DPI: You don't want to discover at the end that the factory quietly substituted a cheaper, lower-grade plastic or fabric halfway through the run.

5. Focus on the 'Worst-Case' Samples (Product-Specific Testing)

Beyond the standard random sampling (often based on AQL), a good DPI includes product-specific functional and performance testing.

The Tip: In addition to a random sample, have the inspector select and test items that represent a higher risk:

✅ Products from a new batch of components.

✅ Products from a machine that recently underwent maintenance.

✅ Products produced after a shift change.

✅ Products subjected to a specific functional test (e.g., turning on an electronic device, checking zipper strength, or weight-bearing capacity).

Why it matters for DPI: Rigorous, product-specific testing helps validate the product's fitness for use, not just its appearance.

6. Document and Track Corrective Actions Rigorously

Finding a defect is only half the battle. The true value of a DPI is ensuring that the factory not only acknowledges the issue but also implements a permanent fix.

The Tip: The DPI report must include a dedicated corrective action plan (CAP) section. For every major defect found, the factory must outline:

✅ The root cause of the problem.

✅ The immediate corrective measure (rework, scrap).

✅ The long-term preventive action (machine calibration, new material training).

Why it matters for DPI: A DPI is a wasted effort if the factory simply fixes the units inspected and then goes back to their old, faulty process.

7. Evaluate Factory Management and Production Flow

A DPI is also an audit of the supplier’s internal quality system. The inspector should observe the efficiency and organization of the floor.

The Tip: Look for red flags in the production environment:

✅ Cluttered and disorganized workstations.

✅ Absence of reference standards (e.g., approved samples or spec sheets) at assembly stations.

✅ Poor handling of rejected or reworked items.

✅ Inadequate storage of semi-finished goods (e.g., sensitive items piled on the floor).

Why it matters for DPI: Operational disarray is a leading indicator of quality inconsistency, and addressing it improves quality across the board.

8. Confirm Final Packaging and Labeling Standards

While final packaging is often checked during a Pre-Shipment Inspection (PSI), a DPI is the ideal time to ensure the inner packaging and labeling are correct and available.

The Tip: Check the following on-site:

✅ Inner retail packaging (are the boxes and bags printed correctly, including barcodes and warning labels?).

✅ Assembly of retail units (are the correct accessories and manuals included?).

✅ Shipping mark specifications (are the outer cartons being marked correctly as they are packed?).

Why it matters for DPI: Correcting a pallet of thousands of mislabeled retail boxes is a logistical nightmare at the very end. Checking early ensures the factory is assembling the final package correctly.

9. Maintain Transparent and Timely Communication

Inspection results must be communicated immediately and effectively to the manufacturing team. Delays in reporting mean more defective products roll off the line.

The Tip: Require the inspector to conduct a debriefing meeting with the factory manager and quality head before leaving the site. All major and critical findings should be reviewed in person, and the factory should sign off on the required immediate corrective actions.

Why it matters for DPI: This real-time feedback loop minimizes the number of non-compliant units produced between the inspection and the receipt of the formal report.

10. Use Data to Drive Continuous Improvement

Every DPI generates valuable data. Don't let that data simply sit in a PDF report. Use it to improve future orders and strengthen your supply chain.

The Tip: Track the following metrics across all DPI reports:

✅ Defect Density: Total number of defects per 1,000 units inspected.

✅ Top 3 Defects: The most recurring issues, which should drive your focus for the next order's Pre Production Inspection (PPI).

✅ Corrective Action Efficiency: The time taken for the factory to successfully implement and verify a fix.

Why it matters for DPI: Over time, this data helps you separate your top-tier suppliers from those who consistently struggle with process control, informing future sourcing decisions.

Conclusion

A During Production Inspection is a vital, non-negotiable step for any brand committed to quality. It provides the necessary visibility into the black box of manufacturing, allowing you to catch issues at a point when correction is feasible, cost-effective, and fast.

Don't let the bulk of your investment hang in the balance until the final inspection. Partner with The Inspection Company to implement a robust DPI strategy and ensure your products meet your exact specifications, every time, on time.