During Production Check (DUPRO) & Inline Inspection (ILI)

During Production Check (DUPRO) And Inline Inspection (ILI) During Production Check (DUPRO) and Inline Inspection (ILI) are mid‑process quality control activities that use Deming-style ratings to measure how well a process is performing and where to improve it. Both aim to catch defects early, stabilize the process, and drive continuous improvement rather than rely only on final inspection.​ DUPRO and Inline Inspection During Production Check (DUPRO) is an on-site inspection carried out when roughly 20–60% of production is completed, often overlapping with what many companies call inline inspection of goods on the line. Inspectors review semi-finished and finished units, processes, and documentation to detect workmanship issues, material nonconformities, schedule risks, and systemic process weaknesses.​ Inline inspection in this manufacturing context refers to checks performed directly on the production line (e.g., at key workstations), sometimes with smaller samples and higher frequency than a formal DUPRO visit. These checks verify product specifications, labeling, packaging, and process controls while production is still flexible enough to be corrected without large scrap or rework costs.​ Applying Deming Ratings Deming’s philosophy focuses on reducing variation, understanding the system, and using data to drive continual improvement instead of relying on inspection alone. A Deming-style rating system during DUPRO and inline inspection therefore emphasizes process capability and stability, not just pass/fail counts. Inspectors and engineers score each key area (e.g., materials, workmanship, process control, delivery risk) on a simple scale such as 1–5 for capability and compliance, supported by objective evidence and defect data.​ These ratings typically combine quantitative indicators (defect rates, rework levels, on-time status) with qualitative assessment (discipline in following work instructions, training level, 5S, problem-solving maturity). The goal is to distinguish between random variation and special-cause problems, then prioritize action on systemic issues (methods, machines, environment) instead of blaming individual operators, which aligns with Deming’s emphasis on improving the system.​ Typical Rating Dimensions In a Deming-oriented DUPRO/ILI checklist, common dimensions for scoring include: Each dimension receives a rating and brief root-cause notes when scores fall below a defined threshold (for example, 3 on a 1–5 scale). This both quantifies risk and supports management review and trend analysis across suppliers, product lines, or time periods.​ Using Ratings for Improvement Deming ratings become useful when they are trended over multiple DUPRO and inline inspections rather than treated as one-off numbers. A supplier with stable, improving scores in process control and material quality can receive reduced inspection frequency, while a supplier with deteriorating workmanship ratings might trigger containment, additional training, or process redesign. Visual tools such as control charts and Pareto analysis of defects can be linked to the rating system so that the team sees which categories most affect quality and delivery.​ The inspection report should translate ratings into concrete actions: containment steps for current lots, corrective actions with responsible owners and due dates, and preventive initiatives such as PFMEA updates or equipment maintenance. This closes the Deming cycle of Plan–Do–Check–Act by using mid-production data (DUPRO and inline inspection) to plan and verify process improvements, rather than relying on final inspection or customer complaints to discover problems. What is Required During Production Check (DUPRO) And Inline Inspection (ILI) During Production Check (DUPRO) and inline inspection require clear criteria, structured data collection, and a Deming-style rating system that focuses on process capability and continuous improvement rather than simple pass/fail judgements. The key requirement is to evaluate not only product quality but also the stability and effectiveness of the production system that creates it. Planning and Preparation Before DUPRO or inline inspection, the buyer and factory must clearly define specifications, sampling plans, defect classifications, and rating scales. This includes approved samples, drawings, packing requirements, and regulatory or customer standards that will be used as references during inspection. Inspectors also need checklists aligned with Deming principles, covering both product and process (materials, methods, machines, people, environment). A Deming rating framework should be agreed in advance, for example a 1–5 scale for key dimensions such as workmanship, materials, process control, documentation, and delivery risk. Each level on the scale must have explicit, objective criteria to minimize subjectivity and to allow comparison across time, products, and suppliers. On-Site Checks During DUPRO During DUPRO, inspectors verify production status (percentage completed, output per day, capacity vs order), ensuring the order is on schedule and that there is enough time for corrective action if issues are found. They select representative samples from different lines, shifts, and stages to avoid bias and reveal systemic problems rather than isolated anomalies. Product checks typically cover workmanship, dimensions, functionality, safety, labeling, and packaging against the approved specifications. Defects are recorded by type and severity (critical, major, minor), and defect rates are calculated. These numerical results feed directly into Deming ratings for product quality and process capability, rather than being treated as isolated inspection outcomes. Inline Process and System Evaluation Inline inspection goes deeper into process behaviour by observing how operators work, how equipment is set and maintained, and how in-process controls are executed. Inspectors verify that standard operating procedures are followed, that inspection/test records are maintained, and that nonconforming products are identified and segregated promptly. From a Deming perspective, special attention is given to sources of variation: machine settings, material lots, training differences, environmental conditions, and changeovers. The requirement is not only to identify defects but to link them back to these systemic causes, so that ratings for “process control” and “system management” reflect the true state of the process, not just the visible outcomes. Deming Ratings Structure A practical Deming rating scheme for DUPRO and inline inspection usually includes at least the following dimensions: Each dimension receives a numerical score plus brief qualitative comments identifying root causes and risks. The requirement is that ratings are evidence-based, supported by measured defect rates, observations, and records, and that low scores trigger corrective and preventive actions rather than blame on individuals. Using Ratings for Improvement After inspection, results are compiled into a structured report where Deming ratings are linked to specific actions, responsible persons, and deadlines. Management then reviews trends