In global manufacturing, the “Golden Sample” you approved months ago often bears little resemblance to what actually rolls off the assembly line on Day 1. Machinery settings drift, workers misinterpret instructions, and suppliers silently substitute materials.
The Initial Production Check (IPC) is the firewall against these early failures. Unlike a Pre-Shipment Inspection (PSI), which finds defects when it’s too late to fix them without massive cost, the IPC catches them when you have only produced 50 units—not 5,000.
This guide provides a definitive operational framework for the IPC, designed for sourcing managers and QA teams who need to stabilize production before the “point of no return.”
What Is an Initial Production Check?
An Initial Production Check (IPC)—sometimes called an Initial Production Inspection (IPI)—is an on-site quality control inspection performed on the first batch of mass-produced goods.
It focuses on the “First Output”: the very first units made using the mass production line, actual raw materials, and factory workers. It verifies that the factory understands your specifications and that the machinery is calibrated correctly.
What IPC Can and Cannot Guarantee
- Can: Confirm that raw materials match the BOM.
- Can: Catch critical setup errors (e.g., wrong mold used).
- Cannot: Guarantee the factory won’t “drift” later (you need DPI for that).
- Cannot: Verify final packaging consistency (too early).
Quick Snapshot: IPC in 60 Seconds
| Feature | Details |
|---|---|
| Timing | When 1% to 10% of goods are produced. |
| Primary Goal | Stop “systemic defects” before mass volume. |
| Key Check | Raw Materials + First Finished Units. |
| Outcome | “Go / No-Go” for continuing mass production. |
| Cost | Low (usually 1 man-day). |
IPC vs Other Production Inspections (Clear Differences)
Don’t confuse IPC with Pre-Production (PPI). PPI checks materials before the line starts; IPC checks the actual line output.
| Inspection Type | Timing | Purpose | Typical Defects Found |
|---|---|---|---|
| Pre-Production (PPI) | 0% (Before start) | Check materials & components. | Wrong raw material, missing parts. |
| Initial Production (IPC) | 1–10% produced | Verify setup & first output. | Wrong color, bad assembly method, mold error. |
| During Production (DPI) | 20–50% produced | Check consistency & schedule. | Drift in size, lazy workmanship, delays. |
| Pre-Shipment (PSI) | 100% produced | Final acceptance. | Random quality issues, damaged packaging. |
When to Schedule an Initial Production Check (Timing Rules)
Scheduling IPC is a balancing act.
- Too Early: The line is running “test samples” with engineers, not the real workers. Result: False confidence.
- Too Late: They have already made 30% of the order. If you find a defect, you have to scrap/rework thousands of units.
Best Triggers for IPC
- New Supplier: You don’t trust them yet.
- New Product/Mold: First time running this design.
- Critical Material Change: You switched from PVC to ABS plastic.
- High-Risk Product: Complex electronics or safety gear.
Readiness Checklist (Before Inspector Arrives)
- BOM Locked: No more “pending” material changes.
- Golden Sample: Signed sample is physically AT the factory.
- QC Tools: Factory has calipers/scales available.
- First Batch: At least 50–100 units finished.
Why IPC Matters (Benefits in the Supply Chain)
- Prevents “The 100% Rework”: Finding a labeling error on Unit #50 costs $5 to fix. Finding it on Unit #5,000 costs $5,000.
- Locks the Process: It forces the factory to “freeze” the method. They can’t change the glue or the screw torque after the IPC without asking you.
- Speed: You get the report in 24 hours. If it passes, the factory runs full speed. If it fails, they stop immediately, saving days of wasted production time.
IPC Inspection Process (Step-by-Step)
1. Planning & Document Review
The inspector reviews your Tech Pack, PO, and the Golden Sample. Tip: If the factory says “We lost the sample,” abort the inspection.
2. Raw Materials Verification
The inspector goes to the warehouse.
- Check: Do the Incoming Quality Control (IQC) records match the BOM?
- Example: You ordered “304 Stainless Steel.” Inspector checks the material certs and does a magnet test.
3. Production Organization Review
- Check: Is there a bottleneck? Are semi-finished goods stored safely?
- Critical: Is there a “Red Box” for defective units, or are they mixed with good ones?
4. Workmanship & Visual Checks
The inspector pulls the first 20–50 finished units.
- Check: Cosmetic defects (scratches, flash, color mismatch).
5. Measurements & Function
- Check: Critical dimensions (fit/function).
- Check: Does it actually work? (On/Off, assembly fit).
6. Packaging Readiness
Even if boxes aren’t packed, check the stock of boxes.
- Check: Barcodes, warnings, thickness of cardboard.
What Inspectors Look for During IPC (Full Checklist)
A) Raw Materials & Components
- Raw material specs match BOM? (Color, grade, thickness).
- Incoming Quality Control (IQC) records exist?
- Storage conditions (dry, off-floor) acceptable?
B) Manufacturing Process
- Work Instructions (SOPs) posted at stations?
- QC staff present on the line?
- Tools/fixtures calibrated?
C) Product Specifications
- Dimensions match drawing?
- Color matches Pantone/Golden Sample?
- Logo placement correct?
D) Product Quality (Workmanship)
- No scratches/dents > 1mm.
- No glue residue / contamination.
- Assembly gaps within tolerance.
E) Packaging Readiness
- Barcode scans correct SKU?
- Shipping marks correct (font, size)?
- Polybag safety warnings present?
Acceptance & Decision Rules (Pass / Conditional Pass / Fail)
The IPC result dictates the factory’s next move.
| Result | Definition | Action |
|---|---|---|
| Pass | No critical/major defects. Process is stable. | Authorize Full Production. |
| Conditional Pass | Minor issues (e.g., label slightly crooked). | Proceed, but fix X by tomorrow. |
| Fail | Critical defect (e.g., wrong material, safety fail). | STOP LINE. Fix root cause. Re-inspect. |
Escalation Rule: If IPC fails, you must schedule a DPI (During Production Inspection) to verify the fix before the final PSI.
Initial Production Check Report (Template)
A good report answers: “Is it safe to run full speed?”
- Production Status: “Factory has 5% finished. Line speed is 200 units/hour.”
- Raw Materials: “Confirmed 304 Steel used.”
- Defect List: “Found 3 units with loose screws (Major). Factory adjusted torque driver.”
- Photos: High-res photos of the first units, the line setup, and the warehouse.
- Recommendation: “Proceed with caution. Check screw torque daily.”
What Happens After an IPC? (Next Steps)
- Immediate Containment: If defects were found, quarantine the bad units.
- CAPA-Lite: Ask the factory: “What did you change to prevent the loose screw?” (e.g., “We calibrated the driver”).
- Lock Changes: Tell the factory: “The process is now frozen. Any changes require written approval.”
Common Issues Found in Initial Production Checks
| Issue | Prevention / Fix |
|---|---|
| Material Mismatch | Factory used “similar” but cheaper plastic. Fix: Reject immediately. Require material certs. |
| Measurement Drift | The mold is cold or machine setting is wrong. Fix: Adjust machine parameters. Re-measure. |
| Missing Labels | “We haven’t printed them yet.” Fix: Check the digital artwork file instead. |
| Dirty Assembly | Workers leaving fingerprints. Fix: Mandate gloves/finger cots immediately. |
FAQ
What is initial production inspection?
A quality check on the first 1–10% of production to verify the manufacturing process and materials.
When should an initial production check be done?
As soon as the first 50–100 units come off the mass production line.
Can IPC replace PSI?
No. IPC checks the start; PSI checks the finish. You need PSI to verify the total quantity and final packaging.
What do inspectors check first?
They usually start with Raw Materials (to ensure the inputs are correct) before checking the finished goods.
IPC vs DPI vs pre-shipment inspection?
IPC = Start (Setup). DPI = Middle (Consistency). PSI = End (Acceptance).
Printable Initial Production Check Checklist (Short Version)
- Inputs: Raw materials match BOM?
- Setup: Work instructions visible?
- First Output: 50 units checked visually.
- Dims: 5 units measured vs spec.
- Function: 5 units tested.
- Pack: Box artwork correct?
- Result: Go / No-Go?