How to structure pre-production, during-production, and pre-shipment inspections when manufacturing in Vietnam — including AQL standards, what to check, and how to find reliable QC partners.
Quality problems discovered after a container has been shipped are expensive. Quality problems discovered during production are manageable. Quality problems prevented by a well-designed inspection program don't happen at all.
This guide covers how to structure quality control when manufacturing in Vietnam — including the three inspection types, AQL standards, what to inspect, and how to find reliable QC partners.
Pre-Production Inspection (PPI)
Conducted before production begins. Inspects raw materials, components, and production samples to confirm the factory has the correct inputs to produce to your specification. Particularly valuable when working with a new factory or launching a new product.
Cost: $250–$400. Timing: Before production start.
During Production Inspection (DUPRO / IPC)
Conducted when 10–40% of production is complete. Allows defects to be corrected before they propagate through the entire run. The most cost-effective inspection for large orders.
Cost: $280–$450. Timing: Early production phase.
Pre-Shipment Inspection (PSI)
Conducted when at least 80% of production is complete and goods are packed. This is the standard inspection most buyers use. It is the last opportunity to identify problems before goods leave the factory.
Cost: $280–$450. Timing: 2–3 days before planned loading.
For orders under $5,000, PSI alone is usually sufficient. For orders over $15,000 or with a new supplier, combining PPI + PSI provides meaningful additional protection.
AQL is a statistical sampling standard that defines the maximum percentage of defective items considered acceptable in a production batch. Inspectors do not check every unit — they use random sampling tables to determine how many units to inspect and what defect rate triggers rejection.
Common AQL settings:
- AQL 0.065: Near zero tolerance. Used for life-safety products, medical devices.
- AQL 1.0: High standard. Common for electronics, toys, children's products.
- AQL 2.5: Industry standard for most consumer goods.
- AQL 4.0: Lower threshold. Sometimes used for commodity goods.
Defects are classified as Critical (immediate safety risk — automatic rejection), Major (functional impairment, likely customer return — fail threshold), or Minor (cosmetic imperfection — pass with notation).
Your inspection order should specify AQL level and defect classification for each item on your specification sheet.
A thorough PSI covers:
Quantity verification: Carton count and unit count match purchase order.
Workmanship: Random sampling against your AQL level for defects.
Measurement/specification compliance: Key dimensions, weight, material composition.
Functionality: Testing that the product works as intended (critical for electronics, mechanical goods).
Packaging and labeling: Correct labeling, barcodes, country of origin statements, regulatory marks (CE, FCC, etc.).
Carton markings: Correct shipping marks, hazard labels if applicable.
Provide your inspection company with a detailed product specification and list of specific defects you want checked. Generic instructions produce generic inspections.
QIMA (formerly AsiaInspection): Strong Vietnam presence, well-designed buyer portal, competitive pricing, fast scheduling.
Bureau Veritas: Global auditing firm with extensive Vietnam operations. More institutional but reliable for compliance-critical products.
SGS: World's largest testing and certification company. Vietnam offices in HCMC and Hanoi.
Intertek: Strong in electronics testing and certification.
Vietnam QC Partners: Smaller local firms can be more flexible and lower cost. Verify accreditation before use.
An inspection failure is not the end of the relationship — it's the start of a structured problem resolution process.
1. Share the full inspection report with the factory immediately
2. Request a corrective action plan with timeline for rework or replacement
3. Commission a re-inspection after the factory confirms correction is complete
4. Do not release final payment until re-inspection passes
Document everything in writing. Your inspection report and the factory's written response form the factual record if the situation escalates to a dispute.
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