Complete Guide to Pre-Shipment Inspection (PSI)
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.
What Is a Pre-Shipment Inspection?
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 most widely used type of quality control inspection in international trade and serves as the last line of defense before goods leave the factory and are shipped to the buyer. During a PSI, a trained third-party inspector visits the manufacturing facility, randomly selects a statistical sample of finished products based on AQL sampling tables defined by ISO 2859-1, and systematically evaluates them against the buyer's approved specifications. The inspector checks product appearance, dimensions, functionality, labeling, packaging, and performs any required on-site tests. The result is an objective, independent pass-or-fail assessment that gives importers confidence in their shipment quality before committing to payment and logistics.
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.
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When Should You Use a Pre-Shipment Inspection?
Pre-shipment inspection is recommended in virtually all import scenarios, but it is especially critical in the following situations:
New Supplier Relationships
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.
First-Time Products
New product launches carry higher quality risk. PSI catches design flaws, material issues, and production errors before they reach your customers.
Large or High-Value Orders
The financial exposure from a large defective shipment can be devastating. PSI provides assurance proportional to the risk.
Products with Regulatory Requirements
Goods subject to safety standards, labeling laws, or import regulations require verification before shipment to avoid customs holds and recalls.
E-Commerce & Amazon FBA Sellers
Negative reviews and returns directly impact your seller rating. PSI helps ensure product quality meets customer expectations before inventory reaches fulfillment centers.
Repeat Orders
Even with established suppliers, quality can drift over time. Periodic PSI maintains accountability and catches process changes that may affect product quality.
The Pre-Shipment Inspection Process — Step by Step
Book the inspection
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.
Provide your quality requirements
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.
Inspector visits the factory
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.
Random sample selection
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).
Product inspection and testing
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.
Defect classification and counting
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.
Inspection report delivery
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.
What Do Inspectors Check During a PSI?
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:
Quantity Verification
The inspector counts finished goods and cartons to confirm the total quantity matches the purchase order. Assortment ratios (sizes, colors, styles) are also verified.
Visual Inspection
Each sampled unit is examined for surface defects, cosmetic issues, color consistency, and overall workmanship against approved samples or reference materials.
Dimensions & Measurements
Critical dimensions are measured using calipers, tape measures, and gauges to verify they fall within the tolerances specified in your product drawings.
Functional Testing
Products are tested for intended functionality — buttons, zippers, moving parts, electronics, power-on tests, and any product-specific performance criteria.
Labeling & Compliance
Care labels, country-of-origin markings, warning labels, barcodes, and regulatory compliance markings are checked for accuracy and legibility.
Packaging & Packing
Inner packaging, carton construction, shipping marks, carton weight and dimensions, and packing arrangement are verified against your packing requirements.
AQL Sampling in Pre-Shipment Inspection
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:
Critical Defects
Safety hazards and regulatory violations. Zero tolerance — any critical defect found results in automatic lot failure.
Major Defects
Functional issues that affect product performance or usability. The industry standard threshold for most consumer products.
Minor Defects
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.
How to Prepare for a Pre-Shipment Inspection
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:
Product Specifications
Technical drawings, material specifications, approved color standards (Pantone references), dimensions with tolerances, weight requirements, and any performance criteria.
Approved Samples
Golden samples or pre-production samples that represent the expected quality standard. Include photos from multiple angles if physical samples cannot be provided.
Packaging Requirements
Inner packaging specifications, carton dimensions and markings, packing arrangement, poly bag requirements, and any retailer-specific packaging guidelines.
Labeling & Artwork
Approved label files, barcode numbers for scanning verification, care instructions, country-of-origin requirements, and any regulatory marking standards.
Special Testing Requirements
Any on-site tests you want performed: function tests, drop tests, barcode scanning, hi-pot testing for electronics, or specific performance measurements.
Defect Classification Guide
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.
Common Defects Found During Pre-Shipment Inspection
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:
Surface Defects
Scratches, dents, chips, stains, discoloration, uneven coating, paint bubbles, rust spots
Functional Failures
Buttons not working, motors not starting, electronics not powering on, zippers jamming, hinges stiff or loose
Dimensional Errors
Products outside tolerance range, inconsistent sizing, misaligned components, uneven gaps
Material Issues
Wrong material used, fabric pilling, weak stitching, brittle plastic, incorrect thickness or weight
Labeling Errors
Missing care labels, wrong barcode, incorrect country of origin, illegible print, missing safety warnings
Packaging Defects
Damaged cartons, missing inner packaging, wrong packing arrangement, incorrect shipping marks, carton weight exceeding limits
Types of Pre-Shipment Inspection vs Other QC Checks
| 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.
Pre-Shipment Inspection Checklist
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.
Quantity Verification
- ✓Total quantity matches purchase order
- ✓Carton count is correct
- ✓Units per carton match packing list
- ✓Assortment and color ratios are correct
Product Appearance
- ✓No visible defects (scratches, dents, stains)
- ✓Color matches approved sample
- ✓Surface finish is consistent
- ✓Printing and logos are clear and correctly positioned
Dimensions & Weight
- ✓Product dimensions within tolerance
- ✓Weight matches specification
- ✓Critical measurements verified with calipers/gauges
Functionality
- ✓All functions operate as intended
- ✓Moving parts work smoothly
- ✓Electrical products power on and function correctly
- ✓Zippers, buttons, snaps operate properly
Labeling & Marking
- ✓Care labels present and correct
- ✓Country of origin marking
- ✓Barcodes scan correctly
- ✓Warning labels as required by destination market
Packaging & Packing
- ✓Inner packaging protects product
- ✓Carton markings match shipping marks
- ✓Carton dimensions and weight are correct
- ✓Export cartons are sturdy and properly sealed
Pre-Shipment Inspection FAQ
What is a pre-shipment inspection (PSI)?
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.
When should I schedule a pre-shipment inspection?
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.
How much does a pre-shipment inspection cost?
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).
What AQL levels are used during a pre-shipment inspection?
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.
What happens if a shipment fails the pre-shipment inspection?
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.
Can I do a pre-shipment inspection myself instead of hiring a third party?
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.
What is the difference between PSI and during-production inspection (DPI)?
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.
How long does a pre-shipment inspection take?
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.
Do I need a pre-shipment inspection for every order?
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.
What are the types of pre-shipment inspection?
The term covers two ideas. First, where PSI sits among the quality inspection types across the production lifecycle: an initial production check (IPC) at the start, a during-production inspection (DPI/DUPRO) at roughly 20–50% output, the pre-shipment inspection (PSI) once 80–100% of the order is packed, and a container loading inspection (CLI) as goods are loaded. Second, PSI itself can be run as a full inspection (every unit checked, used for very small or high-risk lots) or — far more commonly — a random sampling inspection, where a statistically representative sample is drawn under ISO 2859-1 (AQL) and pass/fail is judged against agreed acceptance limits. Most importers use AQL random sampling because it gives reliable quality assurance without the cost of 100% checks.
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