In-Process Inspection (IPI)

A quality control process conducted during the manufacturing or production phase to ensure that materials, components, and finished products meet specifications, standards, and customer requirements before completion. Unlike pre-shipment inspection, which occurs at the final stage, in-process inspection happens at different stages of production to detect and correct defects early, reducing waste, rework, and production delays.

• Why is In-Process Inspection Important?

✔ Prevents defects early in production instead of detecting them at the final stage
✔ Reduces rework, scrap, and production costs
✔ Ensures compliance with specifications and industry standards
✔ Improves process efficiency and reduces delays
✔ Maintains consistent product quality and minimizes customer complaints

• Key Aspects of In-Process Inspection

1. Raw Material and Component Inspection

• Ensure materials meet required specifications before production begins
• Checks for material certification, composition, and dimensional accuracy

2. First Article Inspection (FAI)

• Conducted on the first piece produced to validate setup, tooling, and machine calibration
• Prevents defects from being repeated in mass production

3. Process Monitoring and Quality Checks

• Continuous or periodic inspection during critical stages of production
• Identifies deviations from process standards and corrects them immediately

4. Functional and Performance Testing

• Ensures that the product functions correctly at different production stages
• Conducts stress, load, or endurance tests based on industry requirements

5. Dimensional and Visual Inspection

• Uses measuring tools (calipers, micrometers, CMM, laser scanners) to check tolerances
• Inspects surface defects, finishing, and alignment

6. Welding and Fabrication Inspection

• Checks weld penetration, porosity, cracks, and joint integrity
• Uses Non-Destructive Testing (NDT) methods like Ultrasonic Testing (UT) and Magnetic Particle Inspection (MPI)

7. Documentation and Compliance Verification

• Ensures adherence to ISO, ASTM, API, CE, and other regulatory standards
• Maintains inspection records, reports, and corrective actions for traceability
• When is In-Process Inspection Conducted?

📌 Before production starts (Raw material check)
📌 During production at critical stages (Interim checks)
📌 Before final assembly or finishing (Final process control)

• Conclusion

In-Process Inspection is a proactive quality control method that ensures products meet specifications and industry standards during manufacturing. By detecting defects early, it helps manufacturers reduce costs, improve efficiency, and maintain high-quality production.