Why have my products inspected?

Manufacturers do not always follow your instructions in terms of product quality and detail.

• By inspecting the goods before you pay to ship them, you can be sure that you receive what you expected.
• It is far easier to negotiate with manufacturers to fix product defects before they leave the factory and before you have sent the final payment.
• The knowledge that the goods will be inspected can result in the factory taking more care of the product.
• Don’t assume that the final product will exactly match the sample provided beforehand. It is easier to be sure.

What are the different types of product inspection?

There are three main types of product inspection:

1. Pre-shipment inspection
2. In-production inspection
3. Full inspection
4. Prior to acceptance on delivery into store

A  pre-shipment inspection is where product manufacturing has been completed and the goods are ready to be packed into cartons for shipping. This gives a good indication of the products’ final quality.

In-production inspection is where the product is examined partway through the manufacturing process. This is mainly used when the product is mechanical or similar, and there may be a certain internal piece or process which needs to be checked.

Full inspection is where the entire order is inspected instead of a small sample size like the other two types of inspection. This is good if there is a really high specification or quality level required, or if the product has safety implications and total confidence in it is needed.

Which is the most popular inspection type?

Pre-shipment inspections are a popular choice, they provide a good level of certainty over the final quality. The goods have been fully manufactured and are about to be packed, so they are as complete as possible.

As only a sample of the finished goods is inspected.

Should every order be inspected?

Sometimes businesses will have their first order from a factory inspected, then do away with inspections on subsequent orders. This saves money initially, but assuming that follow-up orders will be of exactly the same quality and standard as the first order can lead to costly mistakes and a lowering of business trust, it can be very expensive.

We highly recommend as a standard procedure every order inspected, even if you have received approved quality products from the manufacturer prior. Factories can often look to expedite costs and lower their production costs thus supplying inferior products on the second or subsequent orders.

Compared to the alternative the inspection cost is an inexpensive way to ensure you are not left with a costly sub-standard order, whether it’s your first time dealing with the supplier or if you have been using them successfully in the past, staff change all the time and so can quality, don't let it be you that pays the price.

What should I ask the inspector to check?

Certified and Reputable inspection companies should have lists for specific types of product they check including:

• Looking for signs of damage
• Checking the product works as it should
• Checking the dimensions of the product
• Check that the product conforms to the standards
• LMATS works with our customers to fine-tune the product inspection procedure to your requirements.

What does a product inspection report contain?

• Inspection reports are comprehensive starting with a description of standard items like the date of inspection, location and factory conditions
• List the products inspected and the defect types found within the sample set. This will normally include both photos of the product from all angles, as well as zoomed-in photos of any defects
• The report will include a pass or fail recommendation, depending on the type of product being inspected purchases should always carefully examine the defects, as sometimes these are not bad enough to fail the order in the inspector’s opinion
• At the end of the inspection process, it is the buyer who needs to decide whether to accept or reject the inspected products
• It is the buyer who has the final say guided by the product inspection report

How many products in the order should be inspected?

• The number of products inspected is dependent on many factors, but in general, inspectors, look to examine around 10%-20% of the order, which is usually a large enough sample size to show up any issues.
• A full inspection includes the entire order, but these take a lot longer and are more expensive. Normally inspecting a sample is enough to show up any areas of concern in the order overall
• In some cases 100% inspection is required due to the sensitivity of the product, ie aviation engine components are 100% inspected.

Why do an in-production inspection?

Especially on a first time order with a new manufacturer, or if the product has a very important part within its manufacturing process, it is sometimes desirable if not mandatory to have it inspected at stages through the production process, any non-conformity issues can be found earlier and rectified before the manufacturing is complete, thus reducing expensive reworks or total losses where the complete batch has to be scrapped.

What to do if the product inspection finds non-conforming issues?

This depends on the non-conformity. If it is minor, you may choose to accept it. If it is major, then you may need to have the supplier fix or replace the faulty products.

• In a replacement scenario, it is always recommended having a second inspection after the non-conformity has been addressed. A second inspection ensures that the supplier does, in fact, fix the issues found. The second inspection should be at the manufacturer’s cost
• There are occasions where product inspections find defects at a level where cancellation of the entire order is the only valid solution
• The key thing is to ensure that the buyer gets what they paid for and that any issues are found before the product is shipped
• There is a significant expense, and potential damage to the buyer’s reputation, if defects are only found when customers start returning the products.

What to do if the manufacturer refuses to make remedy the problems?

Competition for manufacturing is intense, so most factories are very keen to correct any manufacturing issues. They strive to keep the purchaser happy and to receive future orders.

Contracted orders can also set up with protection programs [see trade assistance DEFAT Australia], which may limit payments to the manufacturer until the product has been accepted by the buyer. These also insure against manufacturers not keeping their end of the agreement.

It’s important to have a solid agreement with the manufacturer before the order begins, so both parties know what’s expected and the repercussions if not met.

Rail Weld Ultrasonic Inspection

In accordance with AS 1085.20-2012, Appendix F and Table M2

Rail Alignment

In accordance with AS 1085.20-2012, Appendix E and Table M2
Surface Alignment (Top and Alignment)

Rail Weld Head Hardness Testing

In accordance with AS 1085.20-2012, Appendix G and Tables M2, N3
Traverses conducted 5mm from the Railhead at 2mm indentation spacing in accordance with AS 1817.1 and AS 2205.6.1.
The Railhead hardness has a direct relationship to wear and the amount of Rolling contact fatigue (RCF)experienced. Rolling contact fatigue is  the creation and development of cracks on the running surface of the rail due to contact stresses between the wheel and rail. The propagation of these cracks or fissures could lead to catastrophic rail failure.

Rail Weld Macro (Macroscopic) and Microscopic Examination

In accordance with AS 1085.20-2012, Appendix H, I and Tables M2 and N3
Microstructure: & Martensite:

Rail Weld Slow Bend Test

In accordance with AS 1085.20-2012, Appendix K and Table M2 and N3

Rail weld Web Fatigue Test

In accordance with AS 1085.20-2012, Appendix L3

Rail Weld Surface Visual Inspection

• In accordance with AS 1085.20-2012, Appendix E and Table M2

Inspect the rail for visual signs of defects before the length is ultrasonically tested. The entire weld shall be inspected including the ground weld surface, the heat-affected
zone on both sides of the weld. Identify, record and report evidence (including size and position) of the following:
• Cracks
• Tears
• Gouges
• Gas porosity
• Shrinkage porosity
• Slag or sand inclusions
• Fins
• Electrode burns
• Grinding burns
• Hammer marks
• Abnormal heat-affected zone (HAZ) indications
• Riser break indicators (porosity, gas holes, etc)
• Bolt hole distance (bolt holes must be greater than 65mm from weld)

Advanced Rail NDT Inspection Services

LMATS offers advanced rail inspection availability on request.