What does a PSI checklist include?
Short Answer: Quantity, Appearance, Dimensions, Function, Labelling, Packaging and AQL Classification
A thorough pre-shipment inspection checklist covers seven areas: unit and carton quantity against the purchase order, appearance and workmanship, dimensions and weight against the approved specification, functional testing of every feature, labelling and barcodes, inner and outer packaging, and defect classification under an agreed AQL standard.
The Seven Areas in Order
Each area targets a distinct failure mode. Omitting one is how a shipment passes inspection and still fails on arrival.
| Area | What is checked | Common failure |
|---|---|---|
| Quantity | Units and cartons against the PO | Short-pack inside cartons |
| Appearance | Scratches, dents, paint, logo alignment, colour consistency | Colour variance between lots |
| Dimensions and weight | Measured against the approved spec | Drift from the golden sample |
| Function | Every feature per the spec sheet | Untested secondary features |
| Labelling and barcodes | Origin, materials, care, scannable codes | Non-scanning or wrong-market labels |
| Packaging | Inner and outer carton, shipping marks, drop readiness | Cartons that fail in transit |
| AQL classification | Critical, major and minor counts | Defects recorded without classification |
Write the Checklist Yourself
This is the single highest-leverage habit in quality control and almost nobody does it. A generic checklist finds generic defects; yours finds the ones that matter for your market and your customers.
Understanding the AQL Numbers
Acceptance sampling under ISO 2859-1 turns quality into a decision rule rather than an argument. Knowing the numbers lets you set the standard deliberately instead of accepting a default.
Why Inspection Level Is a Real Decision
Level I costs less because it samples less, and the reduction in catch probability is not marginal. On a 1,000-unit order, Level I pulls 20 samples against Level II's 80, and the chance of catching a defective batch falls from 98% to 64%.
- Level I on anything safety-related A one-in-three chance of missing a bad batch is not a risk profile, it is a gamble.
- Level I on a new supplier You have no history to justify reducing the sample.
- Documented cost of under-sampling Level I on electronics has an average failure cost near $22,000.
- Level II as the sensible default Reduce it only with a supplier whose record actually earns the reduction.
Case: The Feature Nobody Tested
The generic checklist tested power-on and brightness. It did not test the waterproof seal, because the client had not listed it. Roughly 8% of units leaked in the first month of sale. The revised checklist for the next order specified an immersion test with a stated duration and depth.
The Golden Sample's Role in the Checklist
A checklist tells the inspector what to look at. A golden sample tells them what 'correct' looks like. Neither works properly without the other.
How RND SOURCING Builds a Checklist
We start from the client's own complaint and return history rather than a template, because that is where the real defect list lives. Tolerances go in as numbers, market-specific labelling requirements are written out, and the AQL level is set deliberately rather than defaulted. The checklist and the sealed golden sample reach the inspector before the booking is confirmed. For products with a safety-critical feature we push clients towards Level II sampling even when Level I is cheaper, and we say plainly that we are not a testing laboratory.
Build a PSI checklist with usRelated Questions
- What is a 'golden sample' and why send it to the inspector?
- How much does a third-party inspection in China cost?
- Should I do during-production inspection (DPI)?
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