During Production Inspection

By AMREP | Posted on February 27, 2025

Quality isn’t a choice; it’s a commitment that begins the moment production starts. PwC’s Global Manufacturing Report suggests that companies who prioritize quality control during production are 5-6% more profitable than those who rely on post-production inspections.

During production inspection, also referred to as DUPRO, is a quality control process conducted during the manufacturing of a product. It takes place once a certain percentage of production has been completed and is designed to detect any potential issues or defects that could impact the final product’s quality.

In this blog, we will explore what during production inspection entails, why it is so important, the methods involved, and how companies can maximize its benefits.

• What is During Production Inspection?
• Why is During Production Inspection Important?
• The Process of During Production Inspection
• Common Types of During Production Inspections
• Best Practices for Effective During Production Inspection
• Why Choose AMREP Supplier Management Services for Your Quality Control Needs?

What is During Production Inspection?

During production inspection refers to the quality control activities performed while manufacturing is ongoing. This inspection occurs at various stages of the production process, typically after a product has undergone part of its assembly or processing but before the final product is completed.

The goal during production inspection is to detect defects or issues that could impact the quality, functionality, or appearance of the finished product. It helps ensure that the product is progressing as planned and that any necessary adjustments can be made before it reaches the final stage.

Unlike pre-production or post-production inspection, which focuses on the materials or the final product, during production inspection involves evaluating the product while it is still being made. This makes it an essential part of an effective quality control strategy.

Why is During Production Inspection Important?

During production inspection is all centered around ensuring that the product meets the desired quality standards before reaching the customer. Here are some key reasons why it is so important:

1. Early Detection of Defects

The primary advantage of during production inspection is early detection. By inspecting the product during manufacturing, inspectors can spot defects before they become larger problems. Catching issues early in the production process allows for timely corrections, preventing further production of defective items and reducing the overall cost of rework or scrapping products.

2. Prevents Delayed Deliveries

When production issues are detected late in the process, it can lead to delays in shipping and delivery. However, during production inspections ensure that quality problems are addressed promptly, preventing any unexpected bottlenecks that could slow down the manufacturing schedule.

3. Maintains Consistency

For manufacturers producing large quantities of goods, consistency is key. A product must maintain the same quality across all units. During production inspection ensures that each unit is consistent with the specifications, preventing variations in quality that could harm the brand's reputation.

4. Reduces Waste and Saves Money

If defects go undetected during production, it can lead to excessive waste. Products that don’t meet quality standards may need to be scrapped or reworked, both of which incur costs. By catching defects during production, manufacturers can avoid unnecessary waste, save materials, and reduce labor costs associated with rework.

5. Enhances Customer Satisfaction

Quality products lead to happy customers. By conducting effective during production inspections, companies can ensure their products are up to standard, reducing the likelihood of complaints, returns, or warranty claims. This leads to better customer satisfaction and strengthens the brand’s reputation in the market.

The Process of During Production Inspection

The during production inspection process typically follows a series of well-defined steps to ensure the best results. Here's a breakdown of what the process usually involves:

1. Planning the Inspection

Before the actual inspection takes place, it’s important to have a clear plan. This includes determining what products, processes, or stages of production will be inspected. The inspection criteria should be defined clearly, such as dimensions, material quality, or visual appearance.

2. Sampling the Products

Inspectors generally don’t check every single item during production. Instead, they sample a batch of products. The size of the sample depends on various factors, including the volume of the production run and the type of product being manufactured. Statistical sampling techniques may be used to select a representative sample.

3. Inspecting the Products

Once a sample is selected, the inspection begins. Inspectors may check different aspects of the product, such as:

• Material Quality: Ensuring that the right materials are being used in production.
• Dimensions and Specifications: Verifying that the product meets the specified measurements.
• Functionality: Checking that the product performs as expected.
• Appearance: Inspecting for any cosmetic defects, such as scratches, discoloration, or misalignments.
• Packaging: Ensuring that the product is packaged correctly for shipment.

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4. Analyzing the Results

Once the inspection is completed, the results are analyzed. If any defects are found, the inspection team must determine their severity and whether they will affect the product’s functionality or appearance. If the issues are minor, the product may be acceptable, but if they are significant, corrective actions must be taken.

5. Implementing Corrective Actions

If problems are identified during the inspection, corrective actions are necessary. This could involve adjusting machinery, changing materials, retraining workers, or improving quality control procedures. The goal is to address the issue and ensure that it doesn’t affect the rest of the production run.

6. Reporting and Documentation

After the inspection, detailed reports are generated. These reports outline the findings, actions taken, and any recommendations for improving future production runs. Proper documentation is crucial for traceability and can help improve processes in the future.

Read More: Quality Control Skills

Common Types of During Production Inspections

There are several different types of during production inspections that manufacturers can implement based on the needs of their products and processes. Here are a few common ones:

1. Visual Inspection

Visual inspection is one of the most basic and widely used methods during production inspection. It involves checking for visible defects, such as scratches, stains, or misalignment. While simple, it is often very effective, especially for products where appearance is critical.

2. Dimensional Inspection

Dimensional inspection focuses on verifying that the product’s size and measurements meet the required specifications. This type of inspection is crucial for products that require precision, such as mechanical parts or electronics.

3. Functional Testing

Functional testing involves checking whether the product works as intended. For example, if you’re producing electronic devices, you may test the device’s performance, battery life, or other features to ensure it functions properly.

4. Material Testing

During production inspection may also involve testing the materials used in manufacturing. For instance, inspectors may check if a batch of raw materials meets the required specifications for strength, durability, or other properties essential to the finished product.

5. Environmental and Safety Testing

In some industries, products must meet strict environmental or safety standards. During production inspection can involve testing to ensure compliance with regulations related to things like electrical safety, flammability, or toxicity.

Best Practices for Effective During Production Inspection

To make the most of during production inspections, manufacturers should follow best practices that can help optimize the process and maximize its benefits. Here are some key practices to consider:

1. Set Clear Inspection Standards

Before conducting inspections, ensure that you have clear, detailed standards in place. These should outline what is being inspected, how the inspection will be conducted, and the acceptable thresholds for quality. Clear standards ensure consistency and help inspectors make objective decisions.

2. Use the Right Tools and Equipment

The effectiveness during production inspection often depends on the tools and equipment used. Invest in high-quality inspection tools that are appropriate for your product. For example, use calipers for dimensional checks or cameras for visual inspections.

3. Train Inspectors Thoroughly

Properly trained inspectors are key to a successful inspection process. Ensure that your inspection team understands the standards, the methods of inspection, and how to document their findings. Continuous training helps inspectors improve their skills and adapt to new production challenges.

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4. Monitor and Adjust Production Processes

During production inspection can also reveal patterns of recurring defects. Use this information to adjust your production processes. Continuous monitoring and improvements based on inspection data will help minimize defects in future production runs.

5. Automate Where Possible

In industries where high volumes are produced, automation can speed up the inspection process. Automated systems, such as machine vision or automated testing machines, can help identify defects faster and more accurately than manual methods.

6. Communicate Findings Promptly

Once an issue is identified, it is important to act quickly. Prompt communication with the production team ensures that corrective actions are taken immediately, preventing further defects from being produced.

7. Track Performance Over Time

Maintain records of your inspection results to track trends over time. This will allow you to spot areas of the production process that may need improvement and help you measure the effectiveness of corrective actions.

Why Choose AMREP Supplier Management Services for Your Quality Control Needs?

At AMREP Supplier Management Services, we are dedicated to providing comprehensive, reliable, and precise quality inspection services that empower manufacturers to produce defect-free products with confidence. Our commitment to excellence in quality control helps you safeguard your brand’s reputation and meet your customers' expectations, every time. Let us help you ensure that quality is never compromised during production – because at AMREP Inspect, quality is our priority.