Initial Production Check
The initial production check takes place when 1 to 20% of the goods are produced. The inspector checks raw materials under AQL, the manufacturing process and how well the operators understand your requirements, so problems are fixed before mass production.
Also called
- Initial production inspection (IPI)
- Initial production check (IPC)
- Early production inspection
- Start-of-production inspection
Initial production inspection: fix problems before mass production
A defect found on the first 5% of an order costs a few pieces; found at the end, it costs the whole lot.
The initial production check, also called initial production inspection, uncovers raw material issues, misunderstandings with the supplier and other unpleasant surprises while they are still cheap to correct.
It is most useful on a first order, with a new supplier, or when a material or component has changed.
What LPI will do for you during this inspection
This check takes place when 1 to 20% of the goods have been produced.
LPI’s inspector checks a sample of raw materials and components under the AQL standard.
The inspector also reviews the manufacturing process and how well the operators understand your requirements.
The pieces already produced are compared with the approved master sample.
Any other point you are concerned about is checked as well.
Initial Production Check: at a glance
- When
- 1 to 20% of the goods produced
- What is sampled
- Raw materials and components (under AQL) and the first finished pieces
- Compared with
- The approved sample and your specifications
- Duration
- Usually one inspector-day per factory
- Report
- Illustrated, online, within 24 hours
- Booking
- At least 48 hours ahead
What does it cost?
from US$ 268
per inspector-day, excluding tax
Inspections are charged per inspector-day, with travel in Asia and the illustrated report included. The number of days depends on quantity, AQL level, number of models and on-site tests: it is fixed in the quotation, before anything is booked.
See prices and termsHow an initial production inspection runs, step by step
- Checklist and bookingYou send the order, specifications and approved sample photos. We confirm with the factory that production has started and book the date.
- Raw materials and componentsA sample of materials and components is checked under AQL: type, thickness, colour, finish, supplier and test certificates where they exist.
- Production lineThe inspector walks the line: process, tooling, in-process controls, and whether operators have understood your requirements and work instructions.
- First finished piecesPieces already produced are compared with the approved sample: dimensions, workmanship, function, markings.
- ScheduleQuantity already produced and planned output are compared with your shipping date, so a delay is visible early.
- Report and correctionsEvery deviation is reported with photos within 24 hours. The factory corrects before mass production; if the check fails, a production monitoring or a during production inspection follows.
What to send us before the inspection
- Purchase order and specifications
- Bill of materials, with the materials and components you approved
- Photos of the approved (golden) sample
- Test reports or certificates required for the materials
What the factory must have ready
- Production started, with 1 to 20% of the goods made
- Raw materials and components for the order on site
- The production line running on inspection day
- The approved sample and the specifications at hand
- The production manager available to discuss corrections
Defects that start with the materials
Products often reported in the EU for defects that come from a material or a component, which an initial production check can stop before the whole run is made.
| Product | EU alerts | Defects most often reported | What the inspector checks at this stage |
|---|---|---|---|
| Plastic dolls | 21896% China | PVC and plastics used, supplier certificates, samples drawn for phthalate testing. | |
| Fancy-dress costumes | 10791% China | Fabric and accessories against the approved materials, cords, samples for flammability testing. | |
| Lamps and lighting | 33479% China | Cable, plug and components against the approved list, insulation and assembly on the first units. | |
| Fitness equipment | 4957% China | Grips and soft plastics against the approved material, certificates, samples for phthalate testing. | |
| Home decoration | 8969% China | Paints, coatings and plastics against the approved materials, samples for heavy metal testing. |
Source: Safety Gate, the EU rapid alert system for dangerous non-food products, January 2023 to October 2026; figures updated every week in our Quality Observatory. For your own product, see the Product Defects Monitor.
What an initial production check cannot tell you
- The quality of the finished lot: only the pre-shipment inspection judges it under AQL before shipment.
- Defects that appear later: worn tooling, new operators or a new batch of material. A during production inspection or production monitoring covers the rest of the run.
- Chemical compliance of materials, which needs a laboratory test; the inspector can draw the samples.
- Packing and shipping marks, usually not ready yet at this stage.
The six inspections compared
Each inspection answers a different question at a different moment of the order. Most importers start with the pre-shipment inspection, then add earlier checks for new products, new suppliers or large orders.
| Inspection | When | The question it answers | Best for |
|---|---|---|---|
| First Article Inspection | Before mass production, on the first pieces from the series tooling | Do the first pieces match the drawings and the approved sample? | New product, new mould or tooling, new material |
| Initial Production Check | 1 to 20% of the goods produced | Are the materials right, and has the factory understood the requirements? | First order, new supplier |
| During Production Inspection | About 15 to 20% of the goods produced | Is the run staying compliant, and will the shipping date hold? | Large quantities, tight schedules |
| Production Monitoring | Every day, at each stage of production | Are defects removed and reworked as soon as they appear? | Supplier that failed an early check, critical orders |
| Final Random Inspection | Production finished, goods packed | Does the finished lot meet the agreed AQL: ship, rework or sort? | Every order, before the balance payment |
| Container Loading Supervision | Loading day, goods packed and ready to leave | Are the right goods, in the right quantity, loaded safely? | Mixed or fragile loads, several suppliers |
Frequently asked questions
When should I order an initial production check?
As soon as production starts, when 1 to 20% of the goods are produced. It is most useful for a first order or a new supplier, because corrections still cost little.
What does the inspector compare the first pieces with?
The produced pieces are compared with the approved reference sample, a sample of raw materials is checked under AQL, and the inspector verifies the operators understood your expectations. Other points you care about can be added.
Does this check replace the pre-shipment inspection?
No, it complements it. It prevents early defects (materials, misunderstandings), but only the pre-shipment inspection measures the quality of the finished lot before you decide to ship.
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- Minimum notice: 48 hours
- Full illustrated report within 24 hours
- English, French, Chinese, Spanish and Italian spoken