Quality Assurance and Quality Control
Independent quality control: IQC, IPQC and FQC
Product conformity checked at the three points where it is decided: when material arrives, while it is being processed and before it is released.
01What the service involves
Independent quality control places a QUALITAS TR engineer at the supplier to verify product conformity against the purchase order, drawing and specification. Depending on the risk and the product, control is applied at one or more stages: incoming quality control (IQC) of raw materials and bought-out components, in-process quality control (IPQC) at critical operations, and final quality control (FQC) of finished products before packing.
Each control is planned with defined characteristics, methods, sample sizes and acceptance criteria. We record measured values rather than pass marks, classify defects as critical, major or minor and report a clear decision with evidence.
- Material and component identification
- Certificate and traceability check
- Dimensional checks against drawing
- Visual and workmanship inspection
- Functional checks
- Quantity and lot verification
- Marking and labelling
- Defect classification and sampling per ISO 2859-1
02Why buyers need it
Supplier final inspection is not independent and is often sample based at a level chosen by the supplier. Independent control gives the buyer its own evidence before payment or shipment, and incoming and in-process control catch problems while they are still cheap to correct.
For new suppliers or new parts, independent control is also the fastest way to learn where the supplier's process is weak, information that feeds directly into supplier development.
03Typical applications
- New supplier or first production batches
- Critical or safety related components
- Products with a history of field complaints
- Bought-out items from sub-suppliers
- High value machined or fabricated parts
- Products shipped directly to end customers
04Methodology
Control plan
Characteristics, methods, gauges, sampling and acceptance criteria defined from the drawing and specification.
Incoming control
Material certificates, identification, dimensions and condition of incoming material and components checked.
In-process control
Critical operations checked at first-off and at agreed intervals, including set-up approval where relevant.
Final control
Sampling or 100% checks of finished goods, with defects counted and classified.
Decision and report
Lot accepted, accepted with remarks, or rejected. Report with photographs, measurements and nonconformities.
Defect Pareto from final quality control
Typical defect distribution on a batch of machined housings.
Burrs, sharp edges: 34; Thread gauge reject: 19; Surface damage: 12; Bore Ø out of tol.: 9; Missing marking: 5; Wrong coating: 3
05Applicable standards and references
Sampling normally follows ISO 2859-1 with the inspection level and AQL values agreed in the purchase order. General tolerances are interpreted per ISO 2768 when the drawing refers to it, and geometrical tolerances per ISO 1101 or ASME Y14.5 as stated on the drawing.
06Deliverables
- Inspection report with measured values
- Defect list with classification and photographs
- Sampling record (lot size, sample size, Ac/Re)
- Nonconformity reports where applicable
- Inspection release note or rejection notice
- Summary dashboard for multi-lot programmes
07Customer benefits
- Independent evidence before payment or shipment
- Earlier detection of problems at lower cost
- Objective data for supplier performance rating
- Fewer incoming inspection costs at destination
- Clear records for claims and traceability
08How QUALITAS TR supports you
QUALITAS TR engineers carry calibrated hand gauges for routine dimensional checks and use the supplier's calibrated equipment where suitable, after verifying its status. For complex geometries we witness CMM measurement or arrange an independent measurement. We can run single controls or a continuing programme with a fixed inspector who knows the product.
Frequently asked questions
Which sampling plan do you use?
The plan stated in your purchase order. Without one, we propose ISO 2859-1 general inspection level II with AQL values for critical, major and minor defects agreed with you before the inspection. Try the AQL calculator.
Do you report measured values or only pass or fail?
Measured values for every measured characteristic. Pass or fail alone hides trends and makes later disputes harder to resolve.