Inside Our Inspection Flow From Incoming Steel to Delivery

Material Inspection Comes First

Incoming steel is inspected before it reaches the press. Material that fails is returned rather than run, because an out-of-spec strip becomes a defect that only becomes visible after forming and coating, by which point the cost of the error has multiplied.

The First Lot Is a Sample

The first lot off the tool is inspected as a sample before mass production is released. Tooling and setup errors are systematic: caught here they cost one lot, caught later they cost the order.

Random Inspection During the Run

Tools wear and dimensions drift over a long run, so random inspection during mass production covers 30 to 40 percent of output. This is the checkpoint that catches gradual drift rather than sudden failure.

The Ten Percent Rule

Finished goods are inspected against the lot. At or above 10 percent defective, mass production is stopped rather than continued and sorted. Below 10 percent, the affected pieces go to repair or rework and are re-inspected. Having the threshold written down is what stops the decision being made under schedule pressure.

Performance Then Packing Then One More Check

A comprehensive performance inspection of 15 to 20 minutes follows, then packaging to the approved spec, then a final inspection before delivery that checks the packed consignment against the order. Mixed or mislabelled cartons create claims at the customer warehouse, and that last check is what prevents them.

The System Behind the Flow

We maintain a documented quality management system, with procedures covering resource management, process control, verification and continuous improvement, so that the flow above is repeatable rather than dependent on who is on shift.