Learning about product defects and how to avoid them can help you build better products and protect your business from costly lawsuits and penalties. For example, if you’re manufacturing products that need to be packaged in some way, it’s especially important to know about the six main categories of product defects that could cause problems in this stage of the manufacturing process. These are design defects, material defects, manufacturing defects, failure to warn defects, marketing defects, and labeling defects.
1) Manufacturing Defect
Manufacture defects include anything that’s caused by a problem with how a product is made. For example, if you notice mold or cracks on an object that has been sprayed, that would be a manufacturing defect. The good news is that these defects are easy to identify and fix. While most manufacturers and quality control managers will strive to produce defect-free products, we’re only human; mistakes happen! A minor manufacturing error probably won’t affect customers too much – but if it ends up causing harm, your business could face severe legal repercussions. Product recall: If your product causes harm to its users—even after you’ve done everything you can think of to prevent those injuries—you might have to consider issuing a product recall.
An inherent quality or characteristic of a product that makes it unsafe for its intended use. Design defects are often caused by oversights during product development. For example, if a manufacturer is unaware that a plastic bowl might melt when exposed to extreme heat, then an unsafe design may be introduced into production. In order to avoid design defects, manufacturers should anticipate potential risks and make informed decisions about how best to ensure consumer safety. Design defects can be either latent or patent; latent defects aren’t visible from a consumer standpoint but they can still make a product dangerous for everyday use. Patent defects are easy to spot and tend to occur due to manufacturing or quality control errors rather than faulty design choices.
3) Quality Control Defect
A product without a quality inspection service defect is missing or was not produced in accordance with a specification, process, procedure, work instruction, design and/or production plan. An error in manufacture might also cause a quality control defect. The product might contain incorrect materials; material that exceeds manufacturing specifications; or there may be an excessive number of defective items. This type of defect is often introduced before any third party inspection takes place and can be difficult to detect during later stages of production.
4) Inspection Processes
There are a number of ways to categorize product defects, but one effective way is to break them down into categories such as visual, functional, and latent. The acronym AQL (Acceptable Quality Level) has been used for decades in describing defect categories; it describes visual and functional defects. You can use it with your inspection company in China by choosing an AQL level based on how much risk you want to be associated with defective items and then translating that into specifications for each category. For example, you might set an acceptable quality level of 1% (100-200 parts per million) for all visible defects and 10% (1,000-10,000 parts per million) for all latent defects.
5) Handling Damage
Handling damage is a type of product defect that occurs during transportation, storage, or handling before a product reaches its final destination. You can avoid handling damage by double-checking for any physical signs that indicate that a box may have been damaged during transit and then properly inspecting products to ensure they are undamaged. It’s also important to make sure shipping boxes are strong enough to withstand rough handling and aren’t too large or too small. Anything outside these ranges increases your chances of shipping damage, whether it be on the initial shipment or re-shipment. Make sure you know what counts as handled goods versus packaged goods, which are often handled differently since every country has different rules on what is considered acceptable for transport or storage.
6) Labeling Error
Labeling errors result from failure to include all relevant information on a product or its packaging. For example, failure to include instructions or directions is an obvious labeling error. Labelers are also responsible for ensuring that labeling information is accurate and consistent with claims made about products. If consumers expect a product to help them lose weight, for example, and it does not, that’s a serious labeling error that should be corrected immediately.