When & Why
Perform PSI at 80-100% packed to catch defects before export. It is cheaper to fix issues at the factory than after customs clearance. PSI also deters shortcuts because suppliers know checks happen before balance payment.
Planning the PSI
- Choose AQL level (II for general, S-3/S-4 for critical items) and define critical/major/minor defects.
- Share packaging, labeling, and carton drop-test requirements.
- Confirm sampling size from the AQL table; pre-authorize inspector travel and timing.
- Provide golden sample and spec sheet to the inspector.
Execution & Evidence
Inspectors should record:
- Quantity check vs PO
- Workmanship: measure against tolerances and visual defects
- Functional tests: power-on, fit, load, stress where relevant
- Packaging: inner/outer cartons, barcodes, shipping marks
- Photos/videos tagged with lot numbers and timestamps
Acceptance & Rework
Compare defect counts to the AQL accept/reject numbers. If rejected, require rework + re-inspection at supplier cost. Hold the final payment until a pass report is issued and evidence uploaded. Keep the PSI report on file for traceability and future CAPA.