Agree the sampling plan
Pre-shipment inspections normally use a sampling table such as the one referenced by AQL, which sets how many cartons to open and how many defects are accepted. Agree the plan in the order, including the AQL level for critical, major, and minor defects, before production begins.
Ask the inspector to pick cartons at random from the full lot, after at least most of the goods are packed.
Defect classes
| Class | Examples |
|---|---|
| Critical | Sharp or hazardous items in the product, broken zipper that exposes loose fill beads, missing required labels for the destination market. |
| Major | Wrong size or color, open seams, uneven fill, strong odor, damaged carton that exposes the product. |
| Minor | Loose threads, small stains that wipe off, minor stitching irregularity. |
What to check
- Measure dimensions against the approved sample.
- Weigh the finished beds against the target.
- Check the fabric color against the approved swatch under good light.
- Check labels: content, position, and wording.
- Open and close the zipper on a number of units.
- Check carton marks and packed quantity.
- Run a metal needle check where the order requires it.
Records
Take photos of each defect and of the carton marks. The report should list the sample size, each defect found by class, the decision (pass, fail, or conditional), and the corrective action agreed with the supplier. Keep reports by order so you can compare suppliers over time.
If the lot fails
Agree the options with the supplier in writing: rework and reinspect, replace defective units, or accept at a discount. Do not allow shipment of goods that failed a critical class check. Put the rule into your order terms in advance.
Related product line: Orthopedic dog beds. Quotes and specifications are confirmed in writing for each order.