Quality inspection is paramount to ensure that products manufactured meet accepted quality and safety standards. In this article, we looked at quality inspections carried out at the beginning of the manufacturing process. Let’s now look at the type of inspection that you as the manufacturer or accepting customer can order as the final check in the manufacturing process – that last pre-shipment inspection of the product before it leaves the factory for delivery to the customer. This test is known as the Factory Acceptance Test or FAT.

In this comprehensive guide, we’ll explore what the Factory Acceptance Test is, its importance, provide a checklist of what it entails and explain why it’s conducted on the manufacturer’s site.

What Is the Factory Acceptance Test?

The Factory Acceptance Test (FAT) is a rigorous evaluation conducted on equipment or machinery to ensure that it meets predefined specifications and performs as intended before it is shipped to the customer. Essentially, it’s a final quality assurance step before the product leaves the factory floor.

Why is the Factory Acceptance Test (FAT) Important?

The FAT serves as a critical quality control measure, providing assurance to both manufacturers and customers that the product meets expectations. By conducting an FAT, you can identify and address any issues or defects before the product reaches the customer, minimising the risk of costly rework, delays, or customer dissatisfaction.

What Factory Acceptance Test Standards Do We Check For?

Specific standards may vary depending on the industry and product type and we are familiar with all that apply. Common standards include ISO 9001 for quality management systems and ASTM or ASME standards for mechanical equipment. Industry-specific standards and regulations like FDA regulations for medical devices or ASME B31.3 for piping systems may also apply. Our role is to ensure that the relevant standards are met before your product leaves your factory. 

Factory Acceptance Test Protocol

The Factory Acceptance Test Protocol outlines the procedures and requirements for conducting the test. It typically includes:

• Test plan: This is a detailed plan outlining the tests to be conducted, including acceptance criteria and performance standards.
• Test procedures: This provides step-by-step instructions for conducting each test, including equipment set-up, data collection and evaluation criteria.
• Test documentation: This provides comprehensive documentation of test results, including test reports, certificates and any deviations from specifications.

Factory Acceptance Test Checklist

When we conduct a Factory Acceptance Test, we typically follow the following checklist:

• Verification of Specifications: We ensure that the product meets all agreed-upon specifications outlined in the contract or purchase order. This includes verifying dimensions, materials, performance parameters, and any other technical requirements specified by the customer.
• Functional Testing: We conduct thorough functional tests to verify that the product operates as intended under normal operating conditions. We test all functionalities, modes of operation and performance capabilities according to the product’s specifications. We also perform stress testing or endurance testing to assess the product’s performance under extreme conditions or prolonged use.
• Safety Checks: We verify that the product complies with all relevant safety standards and regulations applicable to its intended use, testing features such as emergency stops, overload protection, interlocks and fail-safe mechanisms. We also ensure that warning labels, safety instructions and user manuals are provided and are clearly visible.
• Documentation Review: We review all documentation related to the product, including operation manuals, maintenance instructions, test reports and certificates of compliance, verifying that documentation is complete and accurate and that all necessary revisions and updates have been incorporated.
• Packaging Inspection: We inspect the packaging to ensure that it will protect the product during transportation and handling. To ascertain this, we check for any signs of damage, or improper sealing that could compromise the integrity of the packaging and that packaging materials are correctly positioned to prevent movement or vibration during transit.
• Calibration and Measurement: We calibrate all measurement instruments and test equipment used during the FAT to ensure accuracy and reliability of test results. We also check that all measurement data is recorded accurately and meets established calibration standards.
• Operational Training: Our assurance of standards goes beyond the manufacturer’s responsibilities. We also provide training to the customer’s staff so that they can properly operate and maintain the product and can troubleshoot when needed. We demonstrate key features, functions and operating procedures to ensure that they are familiar with the product’s operation and safety precautions and we address any questions or concerns raised by the customer regarding product operation, maintenance or performance.
• Customer Acceptance: The final stage of the Factory Acceptance Test is to obtain formal acceptance from the customer confirming that the product meets their requirements and expectations. We ensure that customer acceptance is documented in writing, including any conditions or reservations expressed by the customer. We address any outstanding issues or concerns identified during the FAT to ensure customer satisfaction and compliance with contractual obligations.
• By following a comprehensive Factory Acceptance Test checklist, you as the manufacturer can be assured that your products meet quality standards, performance specifications and customer expectations before they are delivered to the customer. 

Why Do We Perform FAT on the Manufacturer’s Site and Not the Customer’s?

Conducting the FAT on the manufacturer’s site offers several advantages. We have access to all necessary equipment, tools and personnel to conduct thorough testing and can provide immediate resolution to any issues uncovered. Having access to the right equipment ensures that all aspects of the product’s performance can be evaluated comprehensively, from functionality and reliability to safety and durability. Manufacturers can customise testing set-ups and configurations as needed to simulate real-world operating conditions and assess the product’s performance under various scenarios. With their skilled personnel on site, we can identify and diagnose issues more effectively during the testing process and gain valuable insights and recommendations for optimising the product’s performance and addressing any deficiencies uncovered during testing.

One of the most significant advantages of conducting the FAT on the manufacturer’s site is the ability to provide immediate resolution to any issues or defects uncovered during testing. Whether it involves troubleshooting technical problems, fine-tuning performance parameters, or implementing design modifications, manufacturers can take swift corrective action to ensure that the product meets all specified requirements and quality standards.

This proactive approach not only accelerates the testing process but also instils confidence in the product’s reliability and performance, demonstrating the manufacturer’s commitment to delivering a high-quality product that meets customer expectations.

So, whether you are a manufacturer seeking the final confirmation that your product meets the required standards before it leaves your factory, or you are the customer needing this verification before accepting delivery of the goods, Global Inspection Managing can support you in conducting the Factory Acceptance Test. Contact us today to find out more.

Validating that your products meet the required contractual and safety standards of manufacture is vital for any manufacturing process. Inspections can take place for incoming raw materials that you use in the manufacturing process or at the very end as a final inspection before the product leaves the factory. However, within the manufacturing process at certain stages, other inspections are needed. 

In this article, we will explore what we call the First Article Inspection, when and why it is needed, what it entails and how it is different from the Production Part Approval Process (PPAP).

What Is a First Article Inspection?

A First Article Inspection (FAI) is a comprehensive examination and verification of the first production item from a new production run or a new part. It involves comparing the physical characteristics, dimensions and performance of the first article against engineering drawings, specifications and quality standards to ensure conformity and accuracy.

When Should a First Article Inspection Occur?

FAI should ideally occur at the onset of a new production run or when introducing a new part into production. It serves as a critical checkpoint to validate that the manufacturing processes are capable of producing parts that meet design specifications and quality requirements.

First Article Inspection Example

To gain a comprehensive understanding of a first article inspection and its essential components, it’s beneficial to examine a First Article Inspection Form.

Similar to other quality processes, a first article inspection requires thorough documentation and mutual agreement among all involved parties. This documentation ensures that the assessment details are recorded accurately and acknowledged by all stakeholders.

Having a documented first article inspection serves as a reference point for both the supplier and the buyer in case of any potential issues arising in the future with the product or production run. It establishes a clear record of the initial assessment for future reference and resolution.

What Happens During an FAI?

During an FAI, inspectors meticulously examine the first production item to ensure that it meets all specified requirements. They verify dimensions, tolerances, material properties and functional performance through a combination of physical inspection, measurements and testing.

How To Conduct an Effective FAI?

Conducting an effective FAI involves several key steps that we include in any First Article Inspection checklist:

• Preparation: We gather all relevant documentation, including engineering drawings, specifications and quality standards and develop a comprehensive FAI plan outlining the inspection methods, sampling plan, and acceptance criteria.
• Physical Inspection: We physically inspect the first article against the engineering drawings and specifications, verifying dimensions, tolerances, surface finishes and material properties.
• Functional Testing: We conduct functional tests to verify that the part performs as intended under normal operating conditions. This may include stress tests, performance evaluations or environmental testing.
• Documentation: We document all inspection results, including measurements, test data, and observations, in a detailed First Article Inspection Report (FAIR) and ensure that the FAIR complies with industry standards. For example, we will conduct an AS9102 First Article Inspection to ensure compliance to the standard AS9102 for aerospace applications.
• Review and Approval: We review the FAIR with you and your customer to obtain approval for production and address any discrepancies or non-conformities identified during the FAI process.

What is the Difference between PPAP and FAI?

While both the Production Part Approval Process (PPAP) and FAI serve as integral components of quality assurance in manufacturing, they are distinct processes designed to fulfil different purposes.

PPAP is a comprehensive product inspection protocol aimed at validating the production process itself. It is primarily concerned with ensuring that parts meet customer requirements consistently over time. PPAP involves a systematic review of the manufacturing process, including documentation of procedures, verification of tooling and equipment, and validation of production capabilities. The goal of PPAP is to establish confidence in the production process’s ability to consistently produce parts that meet specified requirements.

FAI, on the other hand, is specifically focused on the initial production run of a new part or product. Its primary objective is to verify that the first article or prototype of the product meets design specifications and quality standards before full-scale production commences. FAI involves a detailed examination and evaluation of the initial production item, comparing its dimensions, characteristics, and performance against engineering drawings and specifications. The purpose of FAI is to identify any discrepancies or non-conformities early in the production process, ensuring that subsequent production runs meet the desired quality standards.

First Article Inspection is a critical quality assurance process that validates the first production item from a new production run or part introduction. To maintain consistent quality in your production process when you introduce new components, ask us about FAI today.

As a manufacturer, a key part of your manufacturing process is ensuring quality at each stage of production. Incoming Quality Control (IQC) is an important component to the quality assurance process and one of the most critical, being at the start of your production process.

In this article, we’ll explore what IQC is, the risks associated with not incorporating IQC advanced inspection solutions into your processes, and the different types of IQC inspection you should be considering along with the advantages it will bring to your business. We’ll also provide clear insights into the challenges that can arise, what you can expect from your IQC inspector in terms of support during onsite inspection, and how to select an inspection team that is aligned with your quality control objectives. 

What is IQC?

IQC, or Incoming Quality Control, is a quality management process that involves inspecting incoming raw materials or components to ensure they meet predefined quality standards before they are used in your manufacturing process. This can include pre-shipment inspection as well as material inspection. 

From visual inspections that scrutinise surface imperfections to dimensional checks that ensure components fit like pieces of a puzzle, IQC covers every aspect quality control. Consider it the first line of defence to prevent quality issues from infiltrating the manufacturing process. It’s the proactive stance that says, “We won’t compromise on quality, not now, not ever.”

What are the Risks of Inadequate IQC Processes? 

The risks associated with inadequate IQC processes are significant. Using subpar materials in manufacturing can lead to product defects, increased rework or scrap rates, customer dissatisfaction, and even potential safety hazards. Moreover, it can result in production delays and increased costs due to the need for corrective measures or replacements. Let’s take a look at each of these in turn. 

Product Defects: Adopting substandard materials in manufacturing increases the likelihood of defects in the final product. These defects may manifest as structural weaknesses, poor performance, or functional failures, ultimately compromising the product’s reliability and longevity. When these reach the end user, their satisfaction and possible safety, as well as your reputation is a trusted supplier is at risk. 

Customer Dissatisfaction: Delivering products with inferior quality can erode customer trust and loyalty. Dissatisfied customers may voice complaints, request refunds or replacements, and even switch to competitors, again destroying the reputation you have worked hard to establish.

Potential Safety Hazards: In industries where product safety is paramount, such as automotive, aerospace, or healthcare, using subpar materials can pose significant safety risks. Faulty components may lead to equipment malfunction, operational failures, or, in extreme cases, accidents or injuries, exposing both consumers and you as the manufacturer to legal liabilities and reputational damage.

Production Delays: Dealing with quality issues at later stages of production can disrupt workflow schedules and lead to costly delays. You may need to halt production lines, conduct emergency inspections, source alternative materials, or implement corrective actions, all of which contribute to inefficiencies and lost productivity.

Increased Costs: Addressing quality issues post-production incurs additional expenses. Whether it involves reworking defective parts, scrapping unusable materials, or implementing corrective measures, these costs can quickly escalate and eat into profit margins. Moreover, the longer defects go unnoticed, the costlier it becomes to rectify them, as they may have already propagated downstream in the production process.

The way to mitigate these risks is to incorporate IQC inspections into your processes. Investing in robust, professional IQC inspection processes not only safeguards product quality, but also protects against potential financial losses, regulatory penalties and reputational harm. It underscores the importance of proactive quality management strategies that prioritise the integrity and reliability of incoming materials.

What to Expect with IQC Inspection

IQC inspection is the systematic evaluation of incoming materials to verify their quality, conformity to specifications and suitability for use in production as a first line of defence. 

IQC inspections can take various forms depending on the nature of the materials being assessed and the specific requirements of the manufacturing process. They can take the form of Initial Production Check (IPC), During Production Inspection (DUPRO) or  Raw Material Inspection. The following are some of the most common types of IQC inspections: 

Visual Inspection: Often the first step in the quality control process, visual inspection involves a thorough examination with the naked eye of incoming materials for any visible defects or irregularities such as scratches, dents and discolouration. By visually inspecting each material, inspectors can quickly identify any issues that may affect its quality or suitability for use in production. 

Dimensional Inspection: With precise measuring tools such as calipers, micrometers or coordinate measuring machines (CMMs), inspectors can measure components to ensure they meet specified tolerances as well as length, width, depth, diameter, and other dimensions of components. Dimensional inspection is crucial for maintaining product quality and preventing issues related to poor fit or alignment.

Functional Testing: Functional testing assesses the performance and functionality of components to ensure they meet design requirements and specifications. Components are subjected to various tests and simulations to evaluate their performance under real-world conditions. Examples of functional tests include stress testing, endurance testing and performance benchmarking. This proactive approach means you can address potential issues before they impact product quality or performance.

Material Testing: Material testing involves analysing the composition, properties and behaviour of raw materials to ensure they meet quality standards and specifications. Materials can be subjected to chemical analysis, hardness testing and mechanical testing. Chemical analysis identifies the elemental composition of materials, while hardness testing assesses their resistance to indentation or deformation. Mechanical testing evaluates material strength, ductility and other mechanical properties. 

By employing a combination of inspections and testing, you can identify and address potential quality issues early in the production process, minimising risks and ensuring consistent product quality. Let’s look at the advantages IQC inspection brings to your manufacturing business in more detail.

IQC Inspection Advantages

Quality Assurance: We’ve already established that, in manufacturing, quality assurance is essential for ensuring products meet standards. By carefully examining incoming materials, IQC inspection helps maintain the foundation of quality upon which products are built. 

Cost Reduction: By identifying defects early in the production process, IQC inspection helps minimise wastage and the need for expensive rework or warranty claims. This proactive approach saves you money by preventing potential losses and maximising resource efficiency.

Compliance: IQC inspection helps you navigate compliance requirements from various regulations and standards. You avoid costly fines, legal issues and damage to your reputation, ensuring smooth compliance approvals. 

Customer Satisfaction: Ultimately, customer satisfaction is key in any business. IQC inspection contributes to this by ensuring products meet or exceed expectations. IQC inspection helps you deliver consistently high-quality products and build trust and loyalty with customers, creating positive experiences that keep them coming back.

Why You Need an Experienced, Independent ICQ Inspector

Navigating IQC requires the skills of a professional IQC inspector as IQC inspection poses the following challenges among others:

Sampling Accuracy: IQC inspectors must use their experience to select specimens that truly represent the quality of the entire batch. Failure to do so can lead to potential errors in decision-making, where a flawed sample may paint an inaccurate picture of the overall material quality, leading to misguided actions and suboptimal outcomes.

Resource Intensity: Conducting thorough IQC inspections requires a significant investment of resources, which can strain operational efficiency if not managed efficiently. The challenge lies in maximising the effectiveness of inspections without unduly burdening the resources available. Finding this equilibrium requires a keen understanding of priorities, strategic allocation of resources and continuous optimisation of processes to ensure that IQC inspections remain efficient and effective in safeguarding product quality.

Complex Supply Chains: From language barriers to cultural differences, logistical challenges to regulatory disparities, managing IQC across diverse supply chains requires adaptability, flexibility and a willingness to collaborate across boundaries. It’s a test of resilience in the face of complexity, where success hinges on the ability to forge strong partnerships, foster open communication and leverage technology to enhance transparency and traceability throughout the supply chain.

By addressing sampling variability, optimising resource allocation, and fostering collaboration across supply chains, IQC inspection becomes an asset to your business, ensuring that quality remains the cornerstone of manufacturing excellence.

What to Expect from an IQC Inspector

In addition to navigating the challenging minefields we have just mentioned, a qualified IQC Inspector will carry out the following responsibilities:

Conduct Inspections with Precision: An IQC inspector’s primary duty is to conduct inspections on incoming materials with unwavering precision and adherence to established procedures and standards. 

Document and Report: Your IQC Inspector will document inspection results comprehensively and accurately., which serves as an evidence trail, providing transparency and accountability throughout the inspection process. Any non-conformities detected must be reported promptly, initiating the necessary corrective actions. 

Collaborate for Continuous Improvement: As well as being an inspector, your IQC Inspector is an agent of change, actively collaborating with suppliers to address quality issues and implement corrective actions. They serve as ambassadors of quality, fostering constructive dialogue and driving continuous improvement initiatives to enhance efficiency and effectiveness across the board.

Continuously Learn and Adapt: An effective IQC inspector is committed to continuous learning and adaptation, staying abreast of industry trends, emerging technologies, and best practices in quality management. They are the perpetual students of their craft, always seeking new ways to refine and optimise IQC processes for maximum impact.

How to Hire a Reliable IQC Inspector

It’s all well and good knowing the benefits of incorporating IQC Inspection in your manufacturing process and what to expect of an IQC Inspector. But how do you go about hiring the right one for your business? Here’s how to hire the right candidate for the job:

Relevant Experience: Look for candidates with a proven track record of relevant experience in quality control, preferably within your industry or a similar manufacturing environment. Experience breeds expertise, and seasoned inspectors bring valuable insights and insights into the table.

Technical Expertise: Quality inspection is a technical discipline that requires a solid understanding of materials, manufacturing processes and quality standards. Seek candidates with a strong technical background and a keen eye for detail, capable of interpreting specifications and identifying potential quality issues with precision.

Attention to Detail: Look for candidates who demonstrate exceptional attention to detail, meticulousness in their work and a commitment to thoroughness in every aspect of their inspections. A single oversight can have far-reaching consequences, making attention to detail a non-negotiable trait in an IQC inspector.

Communication and Collaboration Skills: An effective IQC inspector must be adept at communication and collaboration, capable of effectively liaising with suppliers, colleagues and stakeholders to address quality issues and drive improvement initiatives. Look for candidates who demonstrate strong interpersonal skills, the ability to communicate clearly and concisely and a collaborative mindset that fosters teamwork and cooperation.

Interview and Assessment: Finally, conduct thorough interviews and assessments to gauge the candidate’s suitability for the role. Ask probing questions to assess their knowledge, experience and problem-solving abilities. Consider practical exercises or simulations to evaluate their inspection skills in action. By investing time and effort in the hiring process, you can ensure that you’re selecting the right candidate to safeguard the quality of your products.

Quality control is an ongoing activity done by every company to ensure that consumer demands and manufacturing standards are continuously met. Unreliable or defective products reaching customers without such routine and strict evaluation can be detrimental to the company’s public image in the long run. Quality control methods are a set of rigorous methodologies or predefined testing processes or steps with the ultimate goal of improving product quality.

Every company strives to deliver products on time without compromising on all quality aspects. Especially in the manufacturing sector where having well-defined quality control techniques that follow industry standards and best practices in place ensures a level of uniformity in the products manufactured.

Through robust quality inspection methods, a company can enhance customer loyalty, get repeat business and new customers from referrals, reduce product recall and improve its market position.
Quality control tools and techniques can vary based on the industry that the products belong to. These should also be in line with the standardized specifications or guidelines set by both national and international governing bodies.

There are two widely used quality control methods:

Method 1 – Quality Inspection 

Quality inspection involves physical inspection and activities, such as measuring, examining, testing or gauging the various characteristics of a product for comparing the results with predefined specifications or requirements. Quality inspection methods apply to components used for production, semi-finished goods and finished goods right before the shipment is done.

By doing a quality inspection, products can be checked physically for defects and if they meet the required quality standards. Quality inspection can include a pre-inspection method, process inspection and a 100% inspection method. Let’s take a detailed look into each of these stages used in quality control techniques:

Pre-Inspection Method

The pre-inspection method involves checking the raw materials when received by the manufacturer and before it goes into the actual production process. This early stage of inspection is especially useful when you want to make sure that only quality materials are used to produce the goods.

The quality control method is used to examine a product prototype or to determine the availability of the right tools in order to work with the delivered raw materials. Catching defects in raw materials itself can save the manufacturer’s time, costs and effort and prevent product recalls arising due to such defects.

Process Inspection

In manufacturing, a process inspection can happen at any point during the production cycle. Process inspection is done to ensure that the various parameters within each section of the process comply with industry standards. Inspecting the product before it gets to the final stage can help in the timely detection of errors or defects saving time and resources. Process inspection can vary based on the industry but these are usually done in three types of intervals:

• Time-based Intervals – Possibly every 2 hours or 2 days based on the machinery.
• Quantity-based Intervals – After a certain production volume is reached, say when every 5 units are produced.
• Freely-defined Intervals – Done at any time depending on the management’s discretion.

100% Inspection Method

A 100% inspection method or full product inspection is when every product of the whole consignment is inspected for quality-related issues. The products are checked for meeting the set standards and the non-acceptable product units are separated. Corrective measures are then taken to avoid repeated mistakes in the product

The size or volume of finished products chosen for the 100% inspection method depends on the required degree of precision. The higher the accuracy degree, the larger the inspection sample will be.

Method 2 – Statistical Control

The statistical quality control method uses various statistical methods or techniques to check the quality of products. These quality control methods are widely used across industries such as food, pharmaceutical and manufacturing units. Statistical quality control methods can be done as part of the production process or as a last-minute quality control check or even as part of the final quality check.

Quality control is the best method to determine variations in products that are caused due to reasons like raw material, consistency of product elements, processing machines, techniques used and packaging applications. The statistical technique helps to detect errors at an early stage so reworks can be minimized.

The two types of statistical quality control methods are acceptance sampling and process control.

Acceptance Sampling

As the name suggests, in acceptance sampling, a sample product is checked for compliance with a predefined quality measurement to ascertain if it falls within the acceptable quality variation limit. Such variations in the product can occur as a result of unexpected or assignable causes.

With this quality control method, the number of defective products reaching the market can be reduced significantly. Acceptance sampling can also be employed to test the performance or efficiency of a product after it has been installed and to compare it with accepted industry standards.

Process Control

Another quality control method that falls under the statistical technique is process control. All activities employed to check whether a particular process is reliable and predictable and results in a consistent performance with the least amount of variation are what process control is all about. This method of statistical analysis can help to improve or control a process so as to achieve desired results.

This quality control technique is used across several industries like power generation plants, chemical processing, food and beverage industry, paper manufacturing and oil refining. The three types of process control methods are:

• Batch process control – where exact quantities of particular raw materials are mixed for a precise period in a particular manner to achieve a specific product.
• Continuous process control – where variables remain the same throughout to produce the product at the best economy, maximum flow rate and given composition.
• Hybrid process control – that can include elements of both continuous and batch process control.

By partnering with a third-party inspection company like Global Inspection Managing, you can be assured that only the best quality control tools and techniques are used for quality control and quality assurance of your products. We operate on the specific guidelines set out in the regulations and legislations governing your specific industry. Our services ensure that businesses across the world are able to maximize their potential and maintain quality standards throughout their operation.