During Production Inspection: Catch Defects While the Line Is Still Running
Most defects in consumer goods sourced from China are not created at packing. They are created mid-line: a mould wears, a material batch drifts, a new operator misreads a spec, a subcontractor swaps a component. By the time finished cartons reach final inspection, correction is expensive — rework, air freight, or a delayed ship date. A during-production inspection (DUPRO, also called an in-process check) moves your visibility upstream, to the point where drift is still cheap to fix.
As part of a sourcing order, in-process checks are carried out against the confirmed pre-production sample (PPS) by the executing inspection party and coordinated by our team. Where you prefer to designate a third-party agency such as SGS, Bureau Veritas, TÜV or Intertek, we coordinate that inspection on your behalf. Either way, the inspection plan — standards, AQL level and checkpoints — is written into your order terms when the order is placed, so nothing is improvised later.
What Is Checked During Production
A DUPRO visit is not a walkthrough. It follows a defined checklist tied to your approved sample and order specification:
- First-piece verification (PQC): the first units off the line are measured and function-tested against the confirmed PPS before volume production continues.
- Materials on line (IQC findings): the actual components, fabrics, coatings and packaging being consumed are compared with approved materials and incoming-inspection records.
- Workmanship drift: stitching, seams, finishes, assembly fit and colour consistency are checked for deviation from the approved standard, not just for absolute defects.
- Semi-finished dimensions and function: critical dimensions are verified (typically within +/-1-5 mm by category) and function tests run early — for example zips cycled 500 times, handle load tests and drop tests on semi-finished units.
- Early packaging samples: labels, warnings, barcodes and retail packaging are checked while there is still time to reprint.
- Production schedule versus plan: output rate and remaining workload are reviewed so a late shipment is flagged weeks ahead, not days.
Category add-ons apply where relevant: small-parts and EN71 checks for toys; colourfastness, pH, formaldehyde and azo dyes for textiles; hardness, coating thickness and torque for hardware; food-contact migration for kitchenware.
At Least Two Visits, on Purpose
Our standard control rhythm includes PPS confirmation and at least two in-production checks covering the run before packing. Two visits are deliberate, because what matters changes across the run. The first visit typically falls early, when tooling and materials are set and the first output can still be corrected cheaply. The second covers the middle and later production, when operator fatigue, material batch changes and schedule pressure tend to introduce new defect patterns. Sampling follows ANSI/ASQ Z1.4 / ISO 2859-1 at standard AQL Major 2.5 / Minor 4.0; stricter levels such as 0.65 or 1.0 are available on request. Critical defects — safety hazards or regulatory violations — are not accepted at any AQL, and the shipment stops.
Findings and Correction While the Line Is Running
Within 24 hours of a visit you receive high-resolution photos, video and a written defect list. Defect patterns are reported the same day, so the factory can correct the line rather than the finished stock. Minor issues are fixed on site, repacked or relabelled. Major issues trigger rework, replacement of shortfalls and re-inspection before release. For serious findings, the case escalates into our 24-48-7 loop: containment and a correction plan first, correction and re-inspection targeted for completion within 48 hours to 7 days, subject to the factory's rework and the executing inspection party's re-inspection schedule, then a re-inspection report with before/after comparison closing the case. Samples and records for every batch are retained for at least 12 months, and you may follow inspections by live video.
DUPRO vs. Pre-Shipment Inspection
| Point | During-production inspection (DUPRO) | Pre-shipment inspection (PSI / OQC) |
|---|---|---|
| Timing | At least twice, during the production run before packing | After production, before shipment |
| What it can still fix | Tooling, materials, process settings, workmanship across the remaining run | Sorting, rework or replacement of affected units; release or hold decision |
| Cost of a failure found | Low to moderate: correction applied before more units are made | High: rework, replacement, re-inspection, possible shipment delay |
Low-risk repeat orders from stable suppliers may rely on PSI alone. New suppliers, new moulds or tooling, regulated categories (toys, textiles, electricals, food-contact goods) and tight ship dates justify DUPRO. The final inspection report is sent to you for confirmation at least 3 days before shipment.
Where a checkpoint raises a compliance question - a missing warning label, an untested material - it is flagged in the same report rather than discovered at final inspection, when the goods are already packed. Testing, where required, is coordinated separately with accredited laboratories; see our product compliance testing page for how that works.
To build in-process checks into your next order, write to [email protected] with your product, destination market and target ship date.