Pilot & First Production Inspection
The inspection between sample approval and mass production
A Pilot Inspection is conducted on the first production run, after sample approval, before full volume commitment. It verifies that the factory has successfully transferred from approved sample to production conditions, using production tooling, materials, and workers.
The gap between sample and production is where most new product quality failures originate. Material substitutions made during tooling. Dimensional variation from production moulds. Assembly shortcuts not visible in handmade samples.
What changes from sample to production
Production tooling has different tolerances than prototype tooling. Production materials may differ from sample materials. Production workers assemble at speed. A pilot inspection catches these inflection points before they scale.
100% inspection option
For safety-critical products, gas appliances, electrical products, and products with certification requirements, QCI can run at 100% inspection rather than AQL sampling. Every unit verified individually.
Book a Pilot Inspection
One inspection before volume commitment. The cost of finding a problem here is a fraction of the cost at mass production scale.