The 5 Common Product Inspection Mistakes You Should Avoid

Inspection Mistakes Could Be Happen!

The goal of product inspection of manufactured goods is to eliminate manufacturing defects. Product inspectors are experts in conducting inspections and identifying possible problems so that manufacturers can rectify them before the products reach the consumers.

Failure to conduct a proper inspection means that fault products can arrive at your customer’s doorstep resulting in catastrophic consequences. However, inspection mistakes don’t always result from carelessness. Factory workers may conduct their work efficiently, but the products may still be subject to errors since other factors such as distractions, and machine errors affect the final quality.

Even with the most detailed instructions to product inspectors, it’s hard to avoid mistakes. This is because quality inspectors are humans like you. For this reason, encountering inspector mistakes in quality control isn’t a surprise. Preparing yourself in advance for such challenges can help you avoid them. You need to be familiar with the common product inspection mistakes and master how to minimize them. Here are the 5 common product inspection mistakes you should avoid.

1. Misunderstanding or Misinterpreting the Product Requirements

Buyers provide product standards to guide the inspectors on what to accept during the inspection. While the inspection specialists may use the requirements as a checklist during the inspection, some may ignore small details.

Furthermore, misunderstanding the specifications can result in products that don’t meet the standards going unnoticed. The product inspector can misinterpret the sizes for shirts inspection. Although their report will indicate the real measurements taken, you are likely to end up with minor issues.

Failing to understand the sizing chart might also result in using an unsuitable method of measurement. This means that the report from the inspector will record inaccurate sizes and can lead to major problems.

Here are some of the ways of avoiding such inspection mistakes:

  • Confirm that the inspector has understood the inspection standards. By contacting the inspector, you will be able to ensure that there is no confusion or ambiguity, which can lead to inaccurate reporting.
  • Use different inspectors. Using more than one inspector will help in avoiding cases where inspectors overlook details. Besides, it’s a great way to prevent the inspectors and the factory officials from developing relationships that could compromise their integrity.

2. Use of Unsuitable Measuring Equipment

Each unit in the product inspection demands the use of specific equipment. Sometimes the inspectors might forget to carry the required equipment, bring unsuitable equipment or one with flaws. Failure to use appropriate equipment can result in various measurement errors. It also leads to erroneous reporting.

One of the ways of avoiding such inspection mistakes is to let the inspector know in advance of the equipment required. Try to be specific, like though providing the right code for colors. Furthermore, you need to ensure that the inspector can perform the inspection has the right equipment. Going for an established inspection company is wise, instead of freelancers or part-time inspectors.

3. Bad Influence from Factory Officials

Some factory officials may misadvise the inspector with regards to quality in a bid to avoid extra costs resulting from rework on the products. For instance, they may persuade the inspector to believe that some defects are minor and shouldn’t be featured in the report.

It’s important that the integrity of the inspector is not compromised. Ensuring that the inspector reports all the defects will help in minimizing inspector mistakes. Always start by emphasizing this issue to your inspection agency.

4. Use of Wrong AQL Sampling Size

The AQL (Acceptable Quality Limit) is a vital tool because it helps the inspector to determine how to perform the inspection. Inspectors use the standard AQL chart to tell the suitable sample size and determine how many rejected products are acceptable. (Click here to use Free AQL Calculator)

A mistake in calculation or interpretation of the AQL levels can lead to erroneous results. The major two errors inspection mistakes when using unsuitable AQL sampling size include:

  • Using a small sample size than agreed upon hence failure to detect defects.
  • Using a big sample size than agreed upon leads to extra expenses on the client.

(Better to understand AQL Table, please Click Here)

Your inspector’s report should indicate the number of items checked and the AQL level used. Compare what’s in the report and what was prearranged with the inspector. If there is any inconsistency, let the inspector know.

5. Lack of Sufficient Photos in the inspection Report

Inspection photos form an important part of the inspection report. It tells you a lot about the units inspected, how the tests were done, and records issues found on the products. Therefore, the lack of enough photos or including wrong photos is a sign of inspector mistakes.

Photos help you to better understand each part of the report and the results of the inspection. For instance, an indication of defects found on the products should be matched by a proof using a photo. Without a photo, it will be hard for you to determine the degree of damage and may not be in a good position to make an informed decision on whether to accept the shipment.

Professional inspectors should let the report be reviewed by the manufacture’s representatives while still at their premises to avoid any conflicting information. If you notice a lack of clarity in the report, contact the inspection agency for clarification. You can also let the inspector know the critical parts of the inspection that you’d like to see their documentation.


People make mistakes, and inspectors are not exceptional. Despite how hard they maintain a high level of professionalism in their work, some mistakes are hard to avoid. A solution is to know how to prevent the occurrence of inspector mistakes that could be costly to your business.

Being informed of these potential mistakes, you can be able to prevent delays and extra expenses. But be sure to take your time when picking an inspection agency. The level of experience of the agency and the training they offer to their inspectors will help you to determine if they fit your requirements. Always go for reputable inspection agencies and avoid cheap ones because the cost of the inspection is proportional to the quality of service they offer.

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Author: AQI Service as a professional quality control service company in China specialized to provide a complete range of quality inspection and testing certification services in China & Asia for global importers, buyers, retailers, and sellers.

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