QC Process Flow

Production and quality control processes are integral facets of manufacturing and service industries, ensuring that products or services meet predefined standards of quality and reliability. The production process involves planning, procurement, manufacturing or service delivery, quality assurance, and packaging/distribution. On the other hand, the quality control process encompasses activities such as quality planning, assurance, control, statistical process control, and continuous improvement, focusing on verifying products or services to specified quality standards

UNDERSTANDING THE STAGES OF QUALITY CHECKS

The quality check process typically consists of several stages to ensure that products meet predefined standards before they are released to customers. These stages include Inline QC, Production QC, and Packaging and Stuffing QC.

1) Inline QC / Pre-Production - Inline QC involves inspecting products at various points during the manufacturing process. This stage focuses on identifying and rectifying any defects or deviations from quality standards as production progresses. It ensures that issues are addressed promptly, minimizing the likelihood of defective products reaching the final stages of production.

2) Midline QC / Production - Production QC occurs after the manufacturing process but before packaging. It involves a comprehensive inspection of finished products to ensure they meet quality criteria and specifications. This stage may include various tests, measurements, and visual inspections to verify product integrity and performance.

3) Endline QC / Packaging & Stuffing QC - Packaging and Stuffing QC takes place after products have been packaged and are ready for shipment. This stage involves examining packaging materials, ensuring proper labeling, and conducting final inspections to guarantee that products are securely packed and in compliance with regulatory requirements. Additionally, it may involve inspecting the stuffing of products into shipping containers to prevent damage during transit.

Pre-Production QC

UNDERSTANDING PI

Once the order is confirmed, the QC team will read the PI, RFQ, specifications, special requirements and other important documents, to understand the order requirement. If any open points are there, the team will note them to get clarification in the premortem call.

PREMORTEM CALL

Prior to releasing the PO to the vendor, the sales, delivery, sourcing, estimation & costing, design, and quality control teams shall hold a premortem call to discuss any open/pending issues.

• Approval of drawings
• Samples
• Accessories & other products
• Special Requirements (For Loading, Unloading, Packaging and Palletization)
• Delivery timelines
• A Production Plan
• Material details to be conveyed to the client

The purpose of this meeting is to collate all the information on the project from all stakeholders, allowing the project to run smoothly and avoid errors at the initial stage itself.

VENDOR EVALUATION

For instance, suppose GlobalFair is working with the vendor for the first time. A detailed evaluation of the factories will be carried out under different aspects, such as financial capacity, catalog depth, material customization, factory R&D, sourcing, warranties, capacity, and equipment. Vendor Evaluation Form draft link.

PO TO VENDOR/ SUPPLIER

QC will review the PO along with the Delivery Team to the vendor once all major open points have been closed and the vendor has been evaluated to ensure all requirements have been captured. As soon as everything is aligned, a PO will be sent to the supplier along with the Good for Production drawing, and the Field Quality Plan for the respective category.

DEBRIEF SESSION WITH VENDOR/ SUPPLIER:

Following the PO issue to the vendor, the QC team and sourcing manager will contact the vendor to explain order requirements, special requirements, packaging, and loading requirements for the project. We will explain to the factory production manager/ QC person, about our client requirements, our quality standards, and QC process to make sure that they give their best output of the product.

PRODUCTION / MIDLINE QC

RAW MATERIAL INSPECTION

2) Raw Material Inspection of Natural Stone Countertops

3) Raw Material Inspection for Rigid Core Flooring

INSPECTION OF FINAL UNITS

After the raw material QC is passed, the factory starts to produce/ fabricate the units as per the drawings/ PO. These individual units will be verified against the approved drawings, approved PO, Field quality plans, Quality and Quantity checklists. Some products like cabinets and flooring will be checked for a quantity of √n + 1 of the entire quantity. And for products like stone slabs and prefab countertops, every piece will be checked by the QC team. Any deviations in the quality will be rejected and the factory reproduce that particular piece.

CENTRAL QC REVIEW

The same information will be documented in the QC APP and sent for a secondary review. A second person will check these images against approved drawings, POs, and Quality & Quantity checklists. Any deviations in quality will be rejected and notified to the factory to rework. QC will be cleared to pack the material into the boxes and pallets once all pieces are verified and aligned with the customer requirements. In case of future needs, all evidences will be stored.

LOADING/ ENDLINE QC

BOX/ PALLET INSPECTION

The QC personnel on-site will inspect each box or pallet before sealing them to confirm all items are correctly packed according to the packing list, preventing any missed pieces during packing and palletization. Once packaging is finished, labels will be affixed to the front of each box to aid customer identification, with box or pallet numbers aligned with the loading plan. Additionally, weights will be noted on each box or pallet to assist customers during unloading. All inspection records will be included in the destuffing manual

LOADING INSPECTION

Upon confirming that packaging meets QC standards, loading clearance will be granted. Loading must adhere strictly to the provided loading plan, with no deviations allowed without prior approval from GlobalFair. The factory will adhere to all aspects outlined in the Loading Field Quality Plan, overseen by the GF QC personnel. Pallets or boxes will be secured with airbags or wooden straps as necessary to prevent movement during transit. A destuffing manual, featuring container loading images and QR codes linking to instructional videos, will be affixed to the first pallet or box near the container door. This aids customers in efficient container unloading within the specified timeframe. The same manual will be shared with customers before the container's arrival, facilitating crew mobilization and equipment preparation

FUMIGATION CHECKS

After ensuring loading compliance with GF standards, QC will authorize container dispatch. Fumigation of boxes or pallets will occur either at the factory or port, with evidence gathered through images or videos

DOCUMENTATION PROCESS

The QC inspection report, packing list, and destuffing manual will be uploaded to the app within 10 days of container dispatch, and then shared with the client.

1) QUALITY INSPECTION REPORT

2) DESTUFFING REPORT

3) FIELD QUALITY PLANS

The Field Quality Plans outline the points to follow during production and quality inspections. They will be sent to the factory along with the purchase order

4) QUALITY PARAMETER CHECKLIST

The Field Quality plans and Quality checklists aid the QC person in verifying the product without deviating from the acceptance criteria and ensuring no points from the Quality plan are overlooked

5) QUANTITY CHECKLIST

The quantity checklists assist the QC team in ensuring that all pieces are packed and loaded into the container without any omissions

OTHER DETAILS

1) ATTENTION TO DETAIL

To prevent customer complaints regarding unwanted spots, our granite slab delivery process emphasizes meticulous attention to detail. We strictly adhere to our thorough field quality plan, which includes a 100% inspection frequency.

2) QUALITY CONTROL ON EDGE PROFILES & SINK CLIP HOLES

To guarantee customer satisfaction and minimize complaints about countertop edge profiles, we conduct checks on edge profiles and sink clip hole positions using tools such as radius gauges, L squares, and digital calipers. This proactive approach has been successful, as we have received no complaints regarding edge profiles and countertop polish quality since implementing these measures.

3) SHADE CONSISTENCY THROUGH COLORIMETER

Ensuring that veins match seamlessly at the seams creates the illusion of continuous counters, resulting in a beautiful and cohesive appearance once installed.

To avoid shade variation complaints in quartz slab deliveries, we thoroughly evaluate each production batch against a counter sample using a colorimeter to ensure consistency. This process includes inspecting 100% of slabs, followed by a secondary review by a dedicated checker before shipping, strengthening our quality assurance measures The graph below compares the slabs from two containers of the same material for a single project. It indicates that the colorimeter delta E values are consistently kept below 1 for both containers. This ensures there is no shade variation between the same material produced in two separate batches.

4) QUALITY CONTROL ON PRE-ASSEMBLY

In our cabinet fabrication process, we perform pre-assembly checks on all hardware, including handles and tab pulls. This ensures accurate hole locations and spacing, guaranteeing a precise fit on drawers and doors. By preemptively addressing any discrepancies, we ensure our customers won't encounter issues, thereby preventing complaints in the future.

QC PERFORMANCE GRAPHS

GlobalFair meticulously documents every complaint, identifying their root causes, and devises preventive actions based on past mistakes to ensure they are not repeated in future orders