Quality Control

Once an inventor or company has decided on a manufacturer and an assembler, it is recommended that you purchase some samples to evaluate quality and request a thorough First Article Inspection (FAI) to ensure that a full run will complete as expected before potentially wasting time and money. While some manufacturers and assemblers have an in-house Quality Control department, not all do, and those that do may not be as thorough for the final product as desired. As a result, these inspections can also be performed at third-party locations.

Check with Quality Control to see if they have a process in place. Manufacturers in the United States are often ISO certified, which means they have procedures in place to ensure product consistency. Some quality processes use calipers to check product measurements by hand, while others use specialized equipment such as a CMM, micro-vu, or comparator.

Also check what your Quality Control's sampling plan looks like. In a full part run where hundreds plus parts are leaving the manufacturer, they typically won't have time to check every single one. What's often done is some sample number is checked per each batch quantity to get a good idea of the quality being released.

Some equipment might not meet the design requirements for precision when it comes to manufacturing tolerances. In such cases, design revisions may be required, or having a backup manufacturer can be a wise move. It can take more time than anticipated to communicate design changes to the manufacturer and obtain revised samples, which many inventors might overlook. Remember that a longer travel time to the manufacturer can prolong this process even more.

Additionally, do not overlook the inspection of the samples for aesthetic flaws. Refrain from accepting a flaw as "satisfactory" if it does not align with the standard you intend for the customer's version. When assessing the quality of an assembled product, it should mimic the intended feel and functionality for the end customer.

Key concepts for a successful production process and maintaining high product quality.

• Quality Check and FAI
  Before production, evaluate manufacturer and assembler quality through samples and First Article Inspection (FAI) to prevent wasted time and money.
  

• Third-Party Inspections
  Consider third-party checks for thorough quality assessment if in-house Quality Control is lacking.
  

• ISO Certification and Sampling
  Verify ISO certification and understand manufacturer's sampling plan to ensure consistent quality in large runs.
  

• Precision and Alternates
  Confirm equipment precision and be prepared for design revisions or backup manufacturers if needed.
  

• Aesthetic Flaws Matter
  Inspect for aesthetic flaws that align with your standard; the final product should mirror intended quality.