In-Process
Quality Inspection.
Every stage of production at YMS is monitored by dedicated IPQC specialists. From the first article approval to the final patrol check -- we intercept defects before they scale.
Compliance
Real-Time
Patrol Inspection
Hourly sampling across all 64 production machines.
±0.1
mm Tol.
AQL
1.0 / 2.5
100%
Check
IPQC Stages
Stage 01
Golden Sample Benchmark Approval
Pass
Approved Before the Line Starts.
Before mass production commences, the first article is pulled from the mold and verified against the approved golden sample. Only after full dimensional, visual, and functional sign-off does the line go into full production.
Material Verification
Confirm 100% food-grade silicone grade, color code, and lot number before shot one.
Dimensional Mapping
All critical dimensions measured against engineering drawings with CMM & calipers.
Visual & Functional Sign-off
QC supervisor, production lead, and engineer co-sign the FAI report.
Machine Settings Locked.
Verified Every Hour.
Temperature, pressure, and curing time are the DNA of silicone quality. IPQC validates every parameter against SOPs throughout the shift.
Mold Temperature
170-200°C
Verified via infrared probe each shift start.
Injection Pressure
80-120bar
Real-time gauge monitoring on every cycle.
Curing Time
60-180sec
Logged automatically per product spec.
Monitoring
Live / 24h
Parameter deviation triggers immediate line audit.
Dimensional & Visual Patrol.
IPQC inspectors walk the line continuously. Precision instruments and trained eyes catch deviations the moment they appear.
Dimensional Patrol
All critical dimensions measured with calibrated instruments, controlled within ±0.1mm tolerance.
Digital Calipers
Accuracy ±0.02mm
Micrometers
Wall thickness check
Projector / CMM
Complex geometry
Gauge Fixtures
Pass / Fail check
Visual Patrol
Zero tolerance for flash, bubbles, color drift, or surface marks.
- No flash / burrs
- No air bubbles
- Uniform color
- Clean surface finish
Products That Actually Work.
Baby products must perform flawlessly. Our IPQC team verifies not just how parts look, but how they feel, fit, and function -- simulating real end-user conditions.
Tensile Pull
Nipples, pacifier handles
Assembly Fit
Bottle + nipple + ring
Leak Test
Bottles, straw cups
Adhesion Test
Printing / silk-screen
Material Toughness
+45% improved
Documented. Traceable.
Audit-Ready.
Every sample pulled, every measurement taken, every judgment made -- captured in time-stamped records aligned with ISO 9001 SOPs.
Hourly Patrol Sampling
5-8 pieces drawn per machine, every hour. Dimensional, visual, and functional data recorded on patrol logs.
AQL Batch Sampling
ANSI/ASQ Z1.4 standard applied per batch. Critical AQL 0.65, Major 1.0, Minor 2.5 per customer spec.
Digital Record Archive
All IPQC reports digitized and retained minimum 3 years. Fully traceable by lot, machine, and operator.
Defects Stop Here.
The moment a non-conformance is identified, products are physically segregated with red-tag labels and moved to a locked isolation zone -- preventing any risk of cross-contamination with good inventory.
Red-Tag Identification
Non-conforming parts tagged with lot, defect type, and inspector ID.
Physical Segregation
Moved to dedicated quarantine area, separated from WIP flow.
MRB Disposition
Rework, scrap, or concession reviewed by Material Review Board.
QUARANTINE
Hold / Do Not Ship
Issues Solved at the Root.
When problems arise, we don't just fix the symptom -- we investigate the root cause and implement preventive measures using disciplined 8D / CAPA methodology.
Identify & Contain
IPQC flags issue, line stops if critical, defective batch contained within 15 minutes.
Root Cause Analysis
Engineer uses 5-Why, Ishikawa or Pareto to pinpoint the real source -- material, mold, machine, or method.
Corrective Action
Parameter reset, mold cleaning, operator re-training, or material lot swap -- executed and verified.
Prevent Recurrence
SOP updated, inspection checklist revised, lessons shared across all production lines.
Data-Driven Quality.
Every inspection feeds into our quality analytics system. We track defect rates, trends, and recurring issues to continuously tighten the process and raise the bar.
<0.3%
Average Defect Rate
99.7%
First Pass Yield
24h
Report Turnaround
3yr
Data Retention
Monthly IPQC Report
Defect Trend
Charts
IPQC is one link in
a four-stage system.
Our quality guarantee begins with raw material inspection (IQC) and ends with final outbound audit (OQC). Explore how every stage works together to deliver zero-defect production.
IQC
Incoming Material Inspection
IPQC ● You are here
In-Process Quality Control
FQC
Final Quality Check
OQC
Outbound Audit