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Pre-shipment inspection is the most critical quality control checkpoint in international trade. This guide covers everything importers need to know — from how PSI works and what inspectors check, to AQL sampling, preparation tips, and common defects to watch for.
A pre-shipment inspection (PSI) — also called a final random inspection (FRI) — is a quality control check conducted at the factory after production is substantially complete (typically 80–100% of the order is finished and export-packed). It is the last line of defense before goods leave the factory and are shipped to the buyer.
During a PSI, a trained inspector visits the manufacturing facility, randomly selects a statistical sample of finished products based on AQL sampling tables, and systematically evaluates them against the buyer's specifications and quality standards. The inspector checks product appearance, dimensions, functionality, labeling, packaging, and performs any required on-site tests.
PSI is the most widely used type of quality control inspection in international trade. It provides importers with an objective, third-party assessment of their goods before payment and shipment — significantly reducing the risk of receiving defective products, non-compliant goods, or incorrect quantities.
Pre-shipment inspection is recommended in virtually all import scenarios, but it is especially critical in the following situations:
When working with a factory for the first time, PSI verifies that the supplier can deliver products meeting your specifications before you commit to payment and shipment.
New product launches carry higher quality risk. PSI catches design flaws, material issues, and production errors before they reach your customers.
The financial exposure from a large defective shipment can be devastating. PSI provides assurance proportional to the risk.
Goods subject to safety standards, labeling laws, or import regulations require verification before shipment to avoid customs holds and recalls.
Negative reviews and returns directly impact your seller rating. PSI helps ensure product quality meets customer expectations before inventory reaches fulfillment centers.
Even with established suppliers, quality can drift over time. Periodic PSI maintains accountability and catches process changes that may affect product quality.
Contact a third-party inspection company like Tetra Inspection and provide your order details: product type, quantity, factory address, and shipment date. Inspections should be booked when production is at least 80% complete.
Share your product specifications, approved samples, artwork files, packaging requirements, and acceptable defect criteria. Specify the AQL levels you want applied for critical, major, and minor defects.
A trained inspector visits the factory on the scheduled date. They verify production status, confirm that at least 80% of the order is finished and export-packed, and begin the inspection process.
The inspector randomly selects units from the finished goods according to the AQL sampling plan. The sample size is determined by your lot size and chosen inspection level (typically General Inspection Level II).
Each sampled unit is inspected against your specifications. The inspector checks appearance, dimensions, functionality, labeling, packaging, and performs any required on-site tests such as barcode scanning, weight checks, or function tests.
All defects found are classified as critical, major, or minor. The inspector counts defects in each category and compares the totals against the AQL accept/reject numbers from the sampling plan.
The inspector compiles a detailed report with photos, defect descriptions, test results, and a clear Pass/Fail/Pending result. The report is typically delivered within 24 hours of the inspection.
A thorough pre-shipment inspection covers multiple aspects of the product and its packaging. The scope depends on the product type and your specific quality requirements, but typically includes the following areas:
The inspector counts finished goods and cartons to confirm the total quantity matches the purchase order. Assortment ratios (sizes, colors, styles) are also verified.
Each sampled unit is examined for surface defects, cosmetic issues, color consistency, and overall workmanship against approved samples or reference materials.
Critical dimensions are measured using calipers, tape measures, and gauges to verify they fall within the tolerances specified in your product drawings.
Products are tested for intended functionality — buttons, zippers, moving parts, electronics, power-on tests, and any product-specific performance criteria.
Care labels, country-of-origin markings, warning labels, barcodes, and regulatory compliance markings are checked for accuracy and legibility.
Inner packaging, carton construction, shipping marks, carton weight and dimensions, and packing arrangement are verified against your packing requirements.
Pre-shipment inspections use AQL (Acceptable Quality Limit) sampling as defined in ISO 2859-1 to determine how many units to inspect. Rather than checking every unit in a production lot — which would be impractical for large orders — AQL provides a statistically valid sample that gives high confidence in the overall lot quality.
The standard AQL values used in most pre-shipment inspections are:
Safety hazards and regulatory violations. Zero tolerance — any critical defect found results in automatic lot failure.
Functional issues that affect product performance or usability. The industry standard threshold for most consumer products.
Cosmetic imperfections that do not affect function. Slightly higher tolerance since these issues are less likely to cause customer complaints.
For example, with a lot of 5,000 units at General Inspection Level II and AQL 2.5 for major defects, the inspector would randomly select 200 units. If 14 or fewer major defects are found, the lot passes. If 15 or more are found, the lot fails. Use our free AQL calculator to determine the exact sample size and accept/reject numbers for your lot size.
Proper preparation is essential for an effective pre-shipment inspection. The more information you provide to your inspection company, the more thorough and relevant the inspection will be. Here is what you should prepare:
Technical drawings, material specifications, approved color standards (Pantone references), dimensions with tolerances, weight requirements, and any performance criteria.
Golden samples or pre-production samples that represent the expected quality standard. Include photos from multiple angles if physical samples cannot be provided.
Inner packaging specifications, carton dimensions and markings, packing arrangement, poly bag requirements, and any retailer-specific packaging guidelines.
Approved label files, barcode numbers for scanning verification, care instructions, country-of-origin requirements, and any regulatory marking standards.
Any on-site tests you want performed: function tests, drop tests, barcode scanning, hi-pot testing for electronics, or specific performance measurements.
A clear list defining which defects are critical, major, and minor for your specific product. This eliminates ambiguity and ensures the inspector applies your quality standards.
Understanding the most common defect types helps you set proper quality expectations with your supplier and define your defect classification guide. Here are the defects most frequently identified during pre-shipment inspections across product categories:
Scratches, dents, chips, stains, discoloration, uneven coating, paint bubbles, rust spots
Buttons not working, motors not starting, electronics not powering on, zippers jamming, hinges stiff or loose
Products outside tolerance range, inconsistent sizing, misaligned components, uneven gaps
Wrong material used, fabric pilling, weak stitching, brittle plastic, incorrect thickness or weight
Missing care labels, wrong barcode, incorrect country of origin, illegible print, missing safety warnings
Damaged cartons, missing inner packaging, wrong packing arrangement, incorrect shipping marks, carton weight exceeding limits
| Inspection Type | Timing | Purpose | Best For |
|---|---|---|---|
| Pre-Shipment (PSI) | 80–100% complete | Final quality verification before shipment | All import orders |
| During Production (DPI) | 20–60% complete | Catch issues early in production | New products, new suppliers |
| Initial Production Check (IPC) | Before mass production | Verify materials and first articles | Complex or custom products |
| Container Loading (CLI) | During loading | Verify quantity and loading quality | Fragile or high-value goods |
| Factory Audit | Before ordering | Evaluate supplier capability | New supplier qualification |
For the strongest quality assurance program, combine PSI with at least one earlier-stage inspection (DPI or IPC) to catch issues before the entire production run is complete. Learn more about our full range of quality control services.
Use this checklist to ensure your pre-shipment inspection covers all critical quality checkpoints. Share it with your inspection provider along with your product specifications.
A pre-shipment inspection (PSI) is a quality control check performed at the factory after production is at least 80% complete. A trained inspector randomly selects samples from the finished goods and evaluates them against your specifications to determine whether the shipment meets acceptable quality standards before it is shipped.
Schedule your PSI when production is 80–100% complete and the goods are packed for export. This ensures the inspector can draw samples from the full production run. Booking too early means unfinished units cannot be inspected; booking too late risks delaying shipment if issues are found.
A standard pre-shipment inspection with Tetra Inspection costs $240 per man-day in Asia & Africa, $340 in South America & Turkey, and $440 in Europe — all-inclusive with no hidden fees. Most consumer product inspections can be completed in a single man-day. Subscription plans reduce the cost further — from $189/man-day (Monthly) to $158/man-day (Annual).
The industry standard AQL levels for PSI are: AQL 0.0 for critical defects (zero tolerance for safety hazards), AQL 2.5 for major defects (functional issues), and AQL 4.0 for minor defects (cosmetic imperfections). These values can be adjusted based on your quality requirements and product type.
If a shipment fails, the inspection report is sent to you with detailed findings. You can then negotiate with your supplier to sort out defective units, rework the products, or produce replacements. A re-inspection is typically scheduled after the supplier has addressed the issues to verify that corrective action was effective.
While you can inspect goods yourself, third-party inspection companies offer significant advantages: trained inspectors with product-specific expertise, objective and unbiased reporting, local presence in manufacturing countries (avoiding travel costs), standardized AQL sampling methodology, and detailed photographic documentation. Third-party reports also carry more weight in supplier negotiations and disputes.
A during-production inspection (DPI) is conducted when production is 20–60% complete, allowing you to catch quality issues early before the full run is finished. A pre-shipment inspection (PSI) is done at 80–100% completion as a final check before shipment. DPI focuses on process and early-stage quality, while PSI focuses on finished product quality and export readiness. For best results, use both.
Most pre-shipment inspections for standard consumer products are completed in one man-day (approximately 8 hours on-site). Complex products, large lot sizes, or inspections requiring specialized testing may require additional time. The inspection report is typically delivered within 24 hours after the on-site inspection is completed.
While not legally required in most cases, PSI is strongly recommended for new suppliers, first-time products, large orders, and high-value shipments. For established suppliers with a proven track record, you may reduce inspection frequency — but periodic PSI is still advised to maintain quality standards over time.
Get the complete pre-shipment inspection guide as a printable PDF.
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