A full inspection service checks every unit against the key items defined for that order, rather than applying a sampling plan. It is the right tool for a narrow set of problems and the wrong default for everything else. The practical question is not whether 100% checking sounds stricter, but whether the defect risk, lot size and unit value justify the inspector time it requires. It is not a guarantee of zero defects, and it does not replace a defined specification, a pre-production sample or a clear AQL plan for the rest of the batch.
What 100% checking covers
In a full inspection, the executing inspectors check 100% of units for the key function and safety-critical items agreed in the inspection plan. The verified practice is 100% on key items such as function and safety, with sampling for the rest. Where you specify appearance sorting, units are sorted against your appearance criteria. Count and assortment are verified unit by unit against the packing list. Defective units are separated for rework or replacement before packing and are not mixed back into the good units.
Quick function checks can be applied to every unit where the test cycle is short and the method is agreed: zip cycling, handle load checks, switch operation or fit checks within the agreed scope. Any critical defect found — a safety hazard or regulatory violation — stops the shipment; the affected batch is quarantined for root-cause review. Category-specific checks can be added to the scope where relevant, provided the method is defined per product and per batch. The inspection plan states which items are 100% checked and which remain sample-based, so the scope is explicit before work starts.
When full inspection is the right choice
- Small lots where sampling tables under ANSI/ASQ Z1.4 / ISO 2859-1 give very small samples, so 100% checking is practical and more informative.
- High-value units where the cost of a single defect justifies individual checking.
- Re-inspection after a failed pre-shipment inspection, where the corrected batch must be proven unit by unit before release.
- Products whose key function can be tested quickly on every unit, such as simple mechanical actions, fit, switch operation or basic electrical function within the agreed scope.
For large, low-value lots with many appearance variables, sampling plus targeted checks is usually more efficient.
Full inspection versus AQL sampling
AQL sampling gives a statistically grounded accept/reject decision at a fraction of the time. Standard AQL Major 2.5 / Minor 4.0 is common; stricter levels such as 0.65 or 1.0 are available on request. Full inspection takes longer and costs more in inspector time, priced per scope. It still cannot promise a zero-defect lot, because it covers the items defined for checking, not every conceivable defect.
| Aspect | AQL sampling | Full inspection |
|---|---|---|
| Basis | Statistical sample under ANSI/ASQ Z1.4 / ISO 2859-1 | Every unit checked against defined key items |
| Decision | Accept or reject the lot | Unit-level separation, rework or replacement |
| Time and cost | Shorter; lower inspector time | Longer; priced per scope |
| Coverage | Sample-based | 100% on agreed function and safety-critical items; sampling for the rest |
| Limit | Sampling risk remains | Cannot promise zero defects beyond the defined check items |
How it is arranged
As part of our inspection services, full inspection is defined in the order terms like any other checkpoint. The items to be checked on 100% of units are listed in writing before the inspection, and the inspection plan is agreed when the order is placed, including standards, AQL level and checkpoints. Results are reported with counts of accepted, reworked and rejected units, high-resolution photos, video and corrective recommendations. The report distinguishes accepted, reworked and rejected counts so you can see the batch outcome before release. The final inspection report is sent to you for confirmation at least 3 days before shipment, and buyers may follow inspections by live video.
If defects are found, the 24-48-7 response loop applies: photos, video and a defect list within 24 hours; containment and a correction plan; correction and re-inspection targeted within 48 hours to 7 days, subject to the factory's rework and the executing inspection party's re-inspection schedule; a before/after comparison closes the case. Samples and records for every batch are retained at least 12 months. For laboratory testing, we coordinate buyer-designated third-party agencies such as SGS, Bureau Veritas, TÜV or Intertek, or accredited ISO 17025 laboratories; we do not issue test reports or certificates in our own name, and laboratory reports are issued by the laboratory and carry its report number. Contact [email protected]. Certificates available upon request.