How to Set Reasonable Quality Expectations for Different Price Tiers

When inspection finds defects, the response protocol matters. First, separate defective from good units. Second, photograph and document each defect type with measurements. Third, notify the factory immediately and pause affected production lines. Fourth, agree on a rework plan and timeline. Fifth, re-inspect after rework before accepting. Don't let the factory rush you — proper corrective action at this stage prevents repeat issues.

Pre-Production Inspection (PPI) is the most cost-effective quality step. It happens when 10-15% of production is complete. At this point, any issues can be corrected before they affect the entire batch. PPI typically checks: first article dimensions against spec, material verification, color/ finish approval, packaging design confirmation, and production line setup. The cost is typically $300-400 and prevents thousands in potential rework.