Day 1-3 of bulk production
1 mandate on-site + 24hr report
AQL 2.5 pre-defined sample size
$180-320 per PO
Critical findings → 2 hours
All 6 verticals · all 8 clusters
What IPC actually checks
The IPC protocol has 22 line items grouped under four headings. Every line is inspected, photographed and logged. The full checklist is shared with the factory 5 working days before production start so there are no surprises.
Raw material verification (6 items)
Brass alloy composition (spectrometer reading vs quoted 60/40 or 65/35), wood species and moisture content (target 10-12%), fabric fibre composition (burn test + microscopy where available), leather grade and tannery certificate (LWG), packaging materials (FSC-certified where required), and hardware (screws, hinges, fasteners) against spec.
Tooling and calibration (5 items)
Verifies the specific tool for your SKU is in the factory (not a nearby similar tool), photographed for identification. Calibration check — typical dimensions on a first-off piece measured against tolerance bands. Wear-and-tear inspection of high-usage tools. Setup consistency across multiple stations. Fixture stability.
First-off comparison (7 items)
First-off pieces from each production line compared against the golden sample (kept sealed at the factory with our signature). Dimensional match, finish match, colour match (colorimeter reading, not eyeball), weight, hardware match, assembly quality, and packaging match. Deviations flagged with photo evidence.
Tech-pack comprehension (4 items)
Interview with the production supervisor: 'Show me where the tech-pack notes X'. Confirms the supervisor has actually read (not just received) the tech-pack. Common failure mode caught: tech-pack in English, supervisor's operating language is Hindi — critical notes lost in translation. We escalate to bilingual re-briefing if needed.
Why IPC is the highest-ROI inspection milestone
Every dollar spent on IPC saves 10-100x downstream. The math is simple: a wrong-alloy brass batch caught on day 1 costs $200 to re-order and 3 days of lead-time slip. The same wrong batch caught at PSI (day 45) costs the entire PO's worth of material scrap, 45 days of re-manufacture, and probably a missed shipment window. We've caught wrong-material batches on 4-5% of first POs across our supplier network — the failure mode is common enough to justify IPC on every new SKU, every new supplier, and every changed material spec.
- Wrong material batch — caught 4-5% of first POs, saves entire PO scrap value.
- Mis-calibrated tooling — caught 2-3% of first POs, saves 30-day rework cycle.
- Tech-pack misunderstanding — caught 6-8% of first POs, prevents systematic defect propagation.
- First-off deviation from golden sample — caught 12-15% of first POs, prevents drift in the rest of the run.
IPC report deliverable
The IPC report lands in your inbox within 24 hours of the inspector leaving the factory. Standard format for consistency across all POs and all suppliers.
- PO reference + factory name + inspector name + inspection date.
- 22-line checklist with pass/fail per line + photo evidence + notes.
- Photograph of the golden sample sealed at factory.
- Photographs of first-off pieces from each production line (typically 3-5 pieces).
- Dimensional measurements against tolerance bands.
- Colorimeter readings against Pantone reference.
- Overall verdict: PASS / PASS with observations / FAIL.
- Critical findings escalated to your team within 2 hours via WhatsApp — not waiting for the report.
When IPC is bundled vs standalone
IPC is included in our full-service Sourcing Company and Buying Office engagements at no additional cost. It's available standalone for buyers who source directly but want independent day-1 QC.
Frequently asked
InitialProductionCheck(IPC)—commonquestions.
When exactly does IPC happen in the production timeline?
Days 1-3 of bulk production, after the factory has completed setup and produced first-off pieces from each line. Not to be confused with pre-production sampling (which happens 3-6 weeks before bulk). IPC verifies bulk production against the approved golden sample.
What's the difference between IPC and DUPRO?
IPC is day 1-3 — checks materials, tooling, first-off pieces. DUPRO is at 30-60% completion — checks in-line QC as the bulk is being produced. Both are needed on high-risk POs; IPC alone is fine for low-risk repeat POs from a proven supplier.
Can IPC be done remotely via video call instead of on-site?
For repeat POs from a proven supplier, yes — remote IPC via live video walkthrough with our inspector on the other end reduces cost to $80-120 per PO. For first POs or new SKUs, on-site is strongly recommended.
What happens if IPC fails?
Critical findings (wrong material, mis-calibrated tool, tech-pack misunderstanding) are escalated to your team within 2 hours via WhatsApp. Production is paused pending corrective action. Rework happens under our supervision; a re-IPC verifies the fix before production resumes. Rework costs are typically borne by the factory (contractual clause in supplier agreements).
How is IPC different from a pre-production audit?
Pre-production audit checks factory capability BEFORE any PO is placed (see /services/factory-audit-india). IPC checks execution AFTER a PO is running. Different scopes, different questions — capability vs execution.
What certifications do your IPC inspectors hold?
Our inspectors are trained internally to AQL 2.5 (ISO 2859-1) protocol with 3-6 months of shadowed field work before running IPCs independently. Senior inspectors hold formal QA qualifications from bodies like ISQEM or IRCA. Full inspector credentials attached to every report.
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