Golden Samples & Improved Quality (DIY & Tools Factory)

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Golden Samples & Improved Quality (DIY & Tools Factory)

So you want to import DIY tools into Europe, you’ve sourced your supplier in Ningbo, China where you place an order for a shipment of a variety of DIY tools like hammers, star and flat screwdrivers as well as 8 meter tape measures. Your shipment arrives, but your hammer handles are the wrong color and the color of the flat and star screwdrivers are swapped around.If you have had these kind of experiences with quality that is below standard or defect rates that you just can’t seem to reduce, you may need to consider establishing a golden sample from your supplier to eliminate any unnecessary areas of risk.

Why?

Sourcing abroad is a challenge. As a means of overcoming this challenge, we recommend establishing a golden sample which is deemed industry best practice. Along with your golden sample you should consider the use of a third-party quality provider to ensure the quality of your sample is of the highest quality.

Why are golden samples important for improved product quality?

A golden sample allows you to evaluate the quality of product that your chosen supplier can produce.

This process gives you a baseline for how you will continue with your supplier. It will showcase how they interpret your product specifications and how they can stick to them.

**Insiders Tip

Have you communicated your product specs clearly?

Product specifications can be sent to your supplier in the form of drawings, sketches or images with the correct dimensions and color specifications. A hammer will have a particular color handle, the same with the screwdrivers, so be sure to mention this in your spec sheet.

There is no such thing as too much. Add everything to minimize any confusion.

Why?

You are up against cultural, language and distance barriers, so be as specific as you possibly can be.

Once you have received your golden sample from your supplier, you will need to evaluate whether the quality level is acceptable or not. Once you approve this, you can then give your DIY tool supplier the go-ahead for mass production.

What goes into approving a golden sample for DIY tools?

You need to make sure that your golden sample has met all product specifications along with the necessary compliance standards and regulations.

How do you go about this?

As you would normally do with production…

By inspection.

Your golden sample can be inspected for any visible defects; you can also send it off to a lab for corrosion and chemical testing.

The corrosion test commonly used according to ISO 9227:2017;

Neutral salt spray (NSS) –  useful for detecting discontinuities, such as pores and other defects, in certain metallic, organic, anodic oxide and conversion coatings.

The type of chemical tests commonly used for plastic handles;

Polycyclic Aromatic Hydrocarbons (PAH) – Is a harmful carcinogenic. A consumer can be exposed when a product comes into direct and prolonged or repetitive contact with the skin or the mouth. High doses of this substance can lead to recalls like the below product;

Mallet recall.jpg

Short chain chlorinated paraffins (SCCPs) – SCCP’s persist in the environment and are toxic to aquatic organisms at low concentrations and bioaccumulate in wildlife and humans, posing a risk to human health and the environment. The below hammer handle contains SCCP’s (A banned substance) as well as PAH and has therefore resulted in a recall of the below hammer;

Hammer recall.jpg

There are three common testing types to ensure improved product quality for your DIY tools like;

  • User testing; this kind of testing evaluates the ergonomics of the tools that have been produced. This evaluation will be based on your product specifications and the overall purpose of the product; e.g., A hammer to hammer nails into walls, so the handle length, grip, and head will be evaluated accordingly. An example of this would be the below axe in which the handle can crack after use, which dislodges the axe head, which poses a serious injury risk to the user or even bystanders.

Axe_Recall_.jpg

  • Comparative testing can also be done. This test is done to evaluate yours against a competitor’s. The functionality, safety, and ergonomics will be evaluated. This kind of test will give you insight into the kind of quality your brand should be achieving.
  • Hardness testing – While this is not a testing requirement, this measurement forms an objective criteria for either the metal or plastic components of the item. For example; the hardness of the metal part of a hammer could affect the performance and durability of the product likewise the plastic could affect the feeling when holding the handle of the product.=

Therefore golden samples are not only used to evaluate acceptable quality limits for your DIY tools factory.

What do I mean?

A golden sample will be of huge value for your third-party quality inspection service provider so that they can compare what has been produced through the mass production process to that of the golden sample.

Key Takeaways

Establishing a golden sample is industry best practice, and it is never recommended to begin your mass production process without an approved sample.

This sample allows you to benchmark your supplier and hold them accountable to your acceptable quality levels.

Key things to remember;

  • Communicate your product specifications clearly. Bear in mind that you are facing cultural, language and distance barriers, so clarity and over communication is an absolute necessity.
  • Approving your golden sample requires due diligence; be sure to send your golden sample for the appropriate inspection and testing.
  • Know your testing and inspection procedures to ensure improved product quality for your brand.

Be sure to remember that your golden sample is reflective of an ideal quality standard from your supplier, and is not a reflection on the mass production process of the factory.

This method of reducing product defects for your brand will help avoid costly delays addressing defects after the fact. Adopting best practice sets you in the best possible position for sustainable and competitive growth.

 

TAKE A DIVE INTO OUR QUALITY INSPECTION GUIDE for IMPROVED PRODUCT QUALITY and reduced defect rates

 

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Cookware Product Specifications Are Key For Quality

Product specifications a small (albeit important) step that requires a bit of technical input, but one that can have a vast implications for the quality of your end product.
Importers today are becoming more aware of defining specifications more clearly than before, so as to manage their product quality more effectively.
You also cannot simply think that showing your supplier an image of the product you would like them to manufacture and expect it to arrive perfectly.

Why?

Sourcing cookware is complex in nature, but sourcing abroad from a foreign country to your own has its own set of challenges that you need to be aware of.
In this blog post, I seek to outline the importance of cookware product specifications for your sourcing strategies and how these industry best practices can set your brand ahead of the rest.

Challenges of sourcing your cookware abroad

Whether you choose to source closer to home or abroad, there is no doubt about the complexities in communication at the best of times. In highlighting the challenges of sourcing abroad we are able to easily identify opportunities for turning these around.

Product quality challenges – The material chosen for production will influence the price and quality of the product. The cookware will need to be tested for extreme high heats and ensure that it is stain resistant when brought into contact with certain liquids. If there are plastic handles on the cookware they will need to be heat resistant.

cookware product specifications

Your cookware should also be chemically tested in a lab to ensure the materials used are in compliance with European regulation.

Compliance problems – You need to ensure that when you select your supplier they are in compliance with all social and environmental standards as internationally laid out. You may need to give them time achieve the relevant compliance documents. Failure to do this and you put your brand and your consumers in a risky position, where trust in your brand is potentially compromised.

In sourcing your cookware abroad you also need to ensure that your products are in chemical compliance according to the chemical FDA and the EU food grade requirements.

It will be important to make sure that you communicate your expectations to your supplier clearly and effectively so as to minimize any comebacks and problems.

Operations and Logistics –  Sourcing your cookware abroad also comes with its fair share of logistical nightmares; from import and export licenses to shipping and packing of containers.

Language – If you are sourcing cookware abroad, the likelihood is that you will encounter language problems, but you can overcome this through the following;

  • Use templates of production and manufacturing information.
  • You may also consider translation for important documents.
  • Consider a third party quality provider with expertise in your sourcing zone and experience in cookware specifications.

Different time zones – If you are based in Europe and sourcing in Asia you will be facing vastly different time zones.

You can send an employee to interact with your supplier on the ground. This is a great opportunity to meet your supplier in person and also see the state of your chosen factory.

Why your cookware product specifications are so important

Now that we have taken a look into the common challenges of sourcing cookware abroad, let’s take a dive into why your cookware product specifications are crucial in defining your products level of quality.

How do you define your product specifications?

You can go about defining your specifications by creating a document that is inclusive of:

  • Pictures or sketched images of your desired end product. This picture or drawing needs to be inclusive of dimensions as well from the sizing to the thickness of metal you require.
  • You need to include what raw materials are required for your product. This is important as your supplier will need to source this if you have not.
  • You absolutely have to include what your destination market is;
    • Why? Your product has to meet certain specified regulatory compliances, it is your responsibility to make sure that it does. E.g. If it is destined for Europe it will need to comply with the EU food grade. If it is destined for the USA it will need to comply with the chemical FDA.

We have included an example of what a product spec sheet may look like; you may want to add or subtract from this, but this is to give an idea of how you can go about filling one out;

Improved product quality

What happens if you don’t send through your product specifications to your supplier?

Defects, recalls, a loss in revenue, brand damage? Not an ideal picture, so let’s take a look at the following examples that highlight the importance defining your product specs clearly and what can happen if you don’t;

A material problem 

The below frying pan poses a risk of burns because the plastic handle becomes too hot, reaching a temperature of 94°C, and no indication is given in the information at the point of sale that the product should be used exclusively on gas or electric (spiral resistance) hot plates.

This product does not comply with the relevant European standard EN 12983 and therefore had to be recalled.

Without specifying the materials needed to create a safe and compliant frying pan destined for the European market place you open yourself up to costly mistakes that can lead to serious loss in revenue and loss of trust in your brand.

Screen Shot 2017-09-14 at 8.08.50 AM.png

Product design issue 

This frying pan is unstable and can tip over unless there is sufficient weight in the frying pan. This unstable design has resulted in serious burn risks as well as the product being recalled.

An expensive mistake to make.

PanSpecs.png

As mentioned above if you are sourcing in Asia, you will encounter language and cultural barriers. There are steps you can take to ensuring your product is perfectly designed and compliant for its destination market.

If you are confident in the product specifications you send to your supplier, be sure to ask them to date and sign it to indicate their acceptance and understanding of your specifications.

Key Takeaways

Sourcing your cookware and kitchenware abroad can have many complexities from language and cultural barriers to the quality and compliance of your product. Developing a sourcing strategy that is based on sound industry best practice will assist in improved product quality that is set to positively position your brand in the marketplace.

Defining your cookware product specifications will go a long way in ensuring low defect rates, you can go about this by;

  • Drawings or renderings with detailed guidelines on size, width, colour etc.
  • Your specification sheet needs to include what raw materials you require
  • Your specification sheet also needs to clearly state which country its destined for, so as to ensure a compliant product.

In clearly defining your cookware product specifications with your supplier you put yourself in a positive position for competitive growth and you also protect yourself from any unnecessary risks.

LET US TAKE YOU THROUGH A STEP-BY-STEP QUALITY INSPECTION GUIDE FOR

YOUR IMPROVED PRODUCT QUALITY

 

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The Ultimate Quality Inspection Guide: 9 Steps To Follow

Quality is what makes (or breaks) a brand and its products. Simple as that. How much time do you actually spend analyzing your quality control systems for focal points that could be the cause of the quality problems you are facing?
Product defects are a reality, for everyone!

The CPSC recently recalled 29 million IKEA chests and dressers that do not comply with the performance requirements of the U.S. voluntary industry standard. This defect resulted in 3 deaths, costing IKEA an amount of $50million for each family in settlement.
Time constraints, lack of resources with ineffectual QMS systems and no guarantees of a perfect quality product often play a role in the number of product defects your supplier produces.

So, how does one avoid costly mistakes that harm their brand and reputation?

We have created a step-by-step guide on how a third party quality provider such as API can help with improved product quality by minimizing defects.
As a professional quality assurance company, we take pride in customizing our quality solutions to that of each of our client’s needs.
This guide addresses the importance of the quality inspection procedures you choose to use for your product and the benefits that they can have for your overall factory performance.

So what can you expect to learn from this?

We walk you through the moment that you touch base with API, to when and who contacts you and how they go about assessing, inspecting and addressing your quality needs and issues every step of the way.

Compliance for improved product quality

  • Tell us everything
    When we say tell us everything we mean it.
    We cover topics such as your exact needs and wants for inspection and testing, as well as discuss what your auditing needs may be. We also follow up on your progress with the Technical Compliance File (TCF) or introduce you to this compliance method.
    These topics help us define the types of questions we need to be answered to better position ourselves in understanding a client’s particular set of needs.
  • Specify everything
    We take you through the specification process and provide you with examples of how you can go about this.
    From dimensions of your product to the colour, to the raw materials, to your packaging requirements, we aim to improve the production process by making this step easy for your supplier to navigate.
    Communication and specification are key.
    An often underrated element of preventing product defects is building a good collaborative relationship with your supplier.
  • Know what your inspection needs are
    Each inspection type is different. This guide takes you through the step-by-step process of each inspection type and what you can expect from each with an outline of their key benefits for you and your end product.
  • Reducing product defects and raising the overall quality of your factory  
    Once all the work is complete, depending on how many inspections were performed,  API provides Key Performance Indicators based on data related insights that were identified through the various inspection reports.

Improved product quality through reportingThis data helps identify any problem areas that may need attention, through this API can then propose improvement strategies. Say, for example, a supplier repeatedly has below standard inspection results, we will then be able to propose a technical audit of the factory to identify root causes and based on that propose any corrective actions, which will, in turn, raise the overall quality of the factory.

**Bonus – We have added checklists to help assist you in improving your product quality.

Product defects are not great, they are what probably keeps you up at night, but in following the quality inspection guide you will begin to reduce the number of defects you experience and in turn will also raise the overall quality of the factory.

This guide is for any importer, retailer, and quality manager who is constantly looking to improve their quality control procedures through the use of an expert third party quality provider that can assist in the following;

  • Raw material inspection solutions
  • Inline, DUPRO and FRI inspection solutions
  • Technical and social auditing solutions
  • Data capturing from checklists and reporting
  • Improvement strategies based on data based insights

A third party quality provider with the appropriate expertise and experience will take you above and beyond in achieving high-quality products and placing you at a competitive position in the market place.

CLICK HERE AND TAKE A DIVE INTO OUR QUALITY INSPECTION GUIDE THAT WILL HELP with Improved PRODUCT QUALITY

 

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How Lego improved CSR with toy quality management system?

Corporate Social Responsibility (CSR) is a must for any toy brand that wants to achieve growth and avoid the costly implications of non compliance. A company that is testament to this fact is Lego. Last year the toy giant reported its highest revenue yet in its 85 year history, their profits rising 1.7% to 12.2bn kroner. This growth showcases the heights you can achieve through organizational commitment. Global retail brands are increasingly wanting to partner with suppliers of children’s toys who can provide them with the appropriate environmental and social compliance. Lego has been able to achieve their CSR goals through going above and beyond what any toy quality management system requires. How have they done this? Renewable energy. In 2012 the toy company began investing in wind turbines to power their operations globally. As a result, in 2016 more than 360 gigawatt hours of energy was used by the LEGO Group to produce the more than 75 billion LEGO bricks sold around the world during the year. Toy quality management systems - renewable energy They initially had committed to making this transition by 2020, but they ended up meeting their target 3 years early! This is one great commitment to the realm of renewable energy. Apart from this they are currently investing loads of money and time into finding alternatives to plastic for their famous building blocks. As consumers increasingly dictate how manufacturers design and make toys, the power of adopting CSR and green initiatives as a part of your competitive strategy will have global results for your brand. What do I mean by this? The toy quality management system you choose to adopt will provide a framework for which CSR is able to be strategically implemented for your brand. Lego is a prime example of this. Whilst they are a children’s toy brand, they have committed fully to sourcing a more environmentally friendly plastic for their iconic plastic blocks. Even though they have not yet found a suitable alternative, their commitment and investment in trying to, puts them at the forefront of an initiative consumers the world over want to see and be a part of. So I put the question to you…

How can your QMS leverage CSR for a globally competitive position?

Let’s take a bit of a deeper dive in… A QMS framework is just that: A framework that has been created to ensure quality in all areas from management to products, to customers, to factory processes and environmental impact. The ISO 14001:15 is the international standard used to navigate environmental impact and innovations. What are the key benefits of complying with ISO 14001:15? 
  • It demonstrates compliance with current regulatory requirements. Toy quality management system - ISO 14001
  • It increases leadership involvement and engagement of employees.
  • It improves company reputation and the confidence of stakeholders through strategic communication.
  • It achieves strategic business aims by incorporating environmental issues into its business management.
  • It provides a competitive and financial advantage through improved efficiencies and reduced costs.
  • It encourages better environmental performance of suppliers by integrating them into the organization’s business systems.
This system provides accountability and creates a platform for building sustainable relationships with your suppliers, as you work together to meet a set of global standards for your toy production.

How can your toy brand go about implementing ISO today?

We have outlined a stepped process which will help you prepare for compliance according to the environmental ISO 14001 framework for your brand;
  • You will need to identify all aspects and environmental impacts of your organization’s activities
  • If you have not established an environmental policy for your organization, you will need to go ahead and do this.
  • You will need to formalize your environmental procedures and publish them in company manuals and company policy.
  • You will need to bring the company into compliance with all legal requirements and mandatory regulations.
  • You will need to get the confirmation of compliance by all stakeholders such as clients and legal authorities.
  • Lastly, you will need to obtain a certification of your environmental management system by a registered third party.
ISO developed these frameworks in which brands are able to optimize their quality systems according to a set of international standards, by international standards it means that consumers can have confidence that their products are safe, reliable and of good quality. The ISO’s standards on road safety and toy safety regulations are just a few of those that help make the world a safer place. As consumers today become increasingly aware of how their favorite brands are attaining goals that closely align with a global value system, it will be important to adopt a toy quality management system that increases your competitive position in the market place. Do you have any questions around environmental auditing solutions? We will be pleased to answer them and help where we can.

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Furniture Inspection Best Practices For Importers

How does one go about skipping on lengthy delays, dodging product recalls and potentially damaging brand reputation that is brought on by furniture quality issues before it’s too late? Importing furniture from South-East Asia is as attractive, if not more, than any other market in the world, but the logistics, compliance, and potential communication challenges it presents does little to guarantee that the standards of quality for your destination market will be met. In this blog post, we seek to outline what you can do to ensure that your furniture reaches you at its highest level of quality, ultimately, to give your brand the competitive advantage it deserves.

Have you determined your DCL (defect classification list)?

This is often a step that is an afterthought, but classifying this, in the beginning, will help to clarify the meaning of your furniture inspection report. This is the most widely used defect category;
  • Critical defect – A critical defect is one that judgment and experience indicate is likely to:
    • result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the products; or
    • Prevent performance of the tactical function of a major end item. A critical defective is a unit of product that contains one or more critical defects.
  • Major defect – A major defect is one, that is likely to result in failure, or to reduce the usability of the product for its intended purpose.
  • Minor defect – A minor defect is one that is not likely to reduce the usability of the product for its intended purpose, or is a departure from established standards having little bearing on the effective or operation of the product.
If there is no established DCL, API has a detailed inspection checklist which will be made available so as to proceed with the inspection.

DUPRO (During Production Inspection) to help resolve your furniture quality issues early on

This is often a critical stage in ensuring that your final piece of furniture will reach its expected level of quality. Referring to the below, 2700 chairs were recalled because of fall hazards that were due to the breaking or bending of the leg. The CPSC found that structural frame of the upholstery chairs was missing a support block to the leg this was against original design. Furniture inspection - DUPRO furniture inspection - DUPRO check
Such as this upholstery chair, you would never check the structure frame inside visually after it is wrapped by fabric when the production was completed.
Furniture inspection complete productA DUPRO inspection could assess some of these critical points at the right moment before the production was completed. DUPRO could focus on finished products, evaluate production status and quality system implemented on the production line. In many cases, a couch or piece of furniture is inspected before the entire purchase order has been completed. This type of inspection means that any problem that has come about should be identified early on and will, therefore, be addressed on site. Your DUPRO inspection report needs to be inclusive of any and all quality issues that were found during the production process. No issue is too small to include.

Update your furniture specifications, based on the DUPRO feedback

Upon receiving your DUPRO furniture inspection report, you will need to go through every step of the report thoroughly. Look at what “pending” results there may be. You should have a strategy in place on how you address these “pending” quality issues. Furniture inspection - redefining product specifications It is at this point that you will need to re-communicate your products specifications to begin addressing those furniture items with “pending” status. Sourcing in Asia is not without communication and language barriers. You can look to overcome these barriers by using a neutral third party quality provider who has the expertise in your sourcing area. Having boots on the ground will ensure that your product specifications are communicated correctly and clearly.

Do a root cause analysis as a preventative measure going forward

It is important to note that a root cause analysis should not be a once off thing that you implement in the odd major defective production case. You should have an RCA strategy of exactly how you will handle defective furniture products with your supplier. Don’t have an RCA strategy? Follow the steps I’ve outline below to help you;
  • Problem Recognition and Definition – Acknowledge and define what your furniture’s production problem is.
  • Identify the causes – Go through the process of cause identification. The trick here is to not spend too much time brainstorming or mind mapping. This needn’t be a time-consuming aspect of the RCA.
  • Identify solutions – Based on your cause identification you will need to identify the best possible solutions to addressing the problem so that it does not happen again.
  • Implement the solutions – If your furniture’s quality was compromised on the production line, you would need to begin implementing the solutions that you were able to identify to prevent any future occurrences of this. The solution needs to be one that optimizes and betters your operational processes. If the proposed solution does not accomplish this, you may need to repeat the above steps to ensure you come up with something that will.
An RCA does not have to be a time-consuming strategy. What it does need to do is highlight the problems and make room for process optimization.

A FRI (Final Random Inspection) is based on sampling inspections

An FRI is a pre-shipment inspection of a small sample of your furniture. This inspection type is used to determine any quality defects that may have come from the production process. preventing product defects - Sample test.jpg A random furniture sample will be selected at this point, where they will each be checked one by one to inspect whether or not they meet the following;
  • Does it meet all of the product specifications as laid out by you?
  • How many visual defects are there?
  • What onsite tests need to be done?

Key Takeaways

The steps as laid out above should be planned and strategized over for each product category that you source. The benefits of the above inspection types;
  • They allow you to detect quality issues early on.
  • A step-by-step analysis of the root cause of the problem which allows you to make sure this problem doesn’t recur.
  • They allow room for re-communication of product specifications.
Analyse every report from every inspection type. If you are not happy to communicate this and communicate what needs to be done differently to meet your required specification. This kind of planning and strategy will see you through the production of high-quality furniture that will positively position your brand in the market place. Have you endeavoured to optimize or customize your inspection solutions? Let us know in the comments section how any of these solutions have been of benefit to your organization. If you have any inspection related questions, please feel free to get in touch with us.

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8 Steps To Limit Risk in Your Toy Testing Procedures

Production competitiveness has become so high in countries like China that suppliers often find ways to cut corners in order to save costs, often putting the quality and safety of your toys, and their extremely vulnerable user base, in jeopardy. When it comes to upholding product safety and compliance, no other consumer goods product is more highly regulated than toys. However, despite stringent requirements and mandatory safety toy testing around the world, unsafe children’s products continue to reach the market today.

As recent as 2017, many importers of the popular ‘fidget spinners’ were found to be selling products in the US that contained alarmingly high levels of mercury and lead leading to mass product recalls and damaged brand reputations.

Non-compliance in the toy industry present a myriad of dangers for brands that can lead to heavy financial losses, unnecessary recalls, and a damaged reputation. It’s reasons like these that quality managers constantly live in fear of quality issues with toys, but it doesn’t have to be this way with strict compliance regulations and proper toy testing procedures.

Improving Your Existing Toy Quality Assurance Processes

Toy quality assurance and toy testing As a quality manager who is responsible for producing toys you know that where quality is concerned the stakes are sky-high. You need to know that toys adhere to the demands of every test they might face when being exported globally to markets with different demands. At API, our quality inspectors and laboratories follow a comprehensive set of 8 toy quality testing steps (built through decades of experience) that helps quality managers effectively manage quality right from the outset. This article will take a brief look at the global toy testing standards themselves, and the step by step procedures API follows to help minimise the risk of quality issues sneaking through and danger of recalls happening, as well as protecting your supply chain and ensuring customer safety and satisfaction.

API’s 8 Step Toy Quality Assurance Process

Click here to watch our comprehensive toy testing process video

1. Preventing Mechanical Risks In The Design Stage

Product Design Specification (PDS) serves as the guideline for understanding the various problems identified early on in the design stage. Possibilities need to be investigated and filtered through various criteria laid out in the PDS to be set forth as practical, viable solutions that require further evaluation.

Through comprehensive design evaluation and hazard assessments, API help you identify potentially dangerous design features and mechanical risks from the outset, helping you save on costly redesign and engineering resources related to product modification, and more serious quality and safety issues later down the line. Furthermore, the evaluation also helps to identify all of the necessary tests that you would need to submit your product to.

2. Preventing Toxic Risks With Raw Materials Testing

Raw material toy testing to ensure toy quality Raw material quality control is paramount in helping to prevent product failure and ensuring a consistent level of quality that you and your customers expect. Making sure that players in your supply chain are continuously subjected to testing of raw materials being used in your toy production, or when they decide to switch suppliers, verifies that the materials are at the level of quality you’re paying for and that no toxic elements such as lead and cadmium finding their way into your finished product. Complying with chemical restrictions in raw materials laid out by the EU and US chemical content regulations such as REACH, EN71 and CPSIA starts with chemical testing. API’s laboratories help to identify toxic elements that can aid you in defining a list of approved materials to be used in the toy production process early on, ensuring your products comply with the limits set for safe use now and into the future.

3. Evaluating Toy Safety Before Mass-Production Through Prototype Testing

The practical solutions and tests identified in the design evaluation stage are embodied in the form of a prototype. The aesthetics, functionality, mechanical aspects, as well as the potential manufacturing issues are all considered, and these aspects need to be thoroughly tested. API’s technical experts are part of technical committees that discuss and write standards for toys, and can ensure you are up to date on the latest developments and discussions on regulation before new regulations are officially published. API’s Hong Kong Laboratory is accredited by HOKLAS to perform laboratory testing for the European, American and Australasian markets. The three main areas of testing are:

1) ‘Mechanical and Physical Properties’

  • Drop Test
  • Compression Test
  • Torque Test
  • Tension Test
  • Flexure Test
  • Bite Test

2) ‘Flammability’

  • Conducted on  toys to examine their flammability characteristics

3) ‘Restricted Substances – Chemical Testing’

  • Lead content test
  • Cadmium content test
  • Phthalate content test
  • Other applicable chemical tests

Prototype testing helps to identify the shortcomings of initial toy design and how they will hold up in real use case scenarios.

Toy testing at a factory

Evaluate your Factory

Perform a quality management audit with specific points related to toys, such as ensuring that sharp tool equipment and a broken needle policy has been used and properly calibrated. It is also important to ensure that your factory has also established traceability system for identification and tracking materials through production. Through this testing process, API helps you to further refine the product design and remove any obstacles that may detract from the original concept by making it safer for use, and ultimately, preventing the need for costly recalls well before the products hit the production line. On top of this testing process, API are also entitled to issue certificates of conformity as a ‘Notified Body’.

4. Ensuring Compliance Through All Inclusive Compliance Software

Whether your brand is directly or indirectly affected by Directive 2009/48/EC, it is of vital importance to ensure the collection and gathering of all the necessary technical documentation needed from your manufacturer to demonstrate the conformity of the product to the applicable requirements of the TSD.

It is up to your product manufacturer to draw up this technical documentation, or request it from relevant parties, and keep it and the EC declaration of conformity for a period of 10 years after the toy has been placed on the market. It is up to you as the importer to ensure that the manufacturer fulfills this duty, that the toy bears the required conformity marking, and is accompanied by the required technical documents. These documents must be made available to national surveillance authorities upon request for the same period of time to demonstrate conformity of the toy. Technical documentation to be drawn up and collected must be presented in one of the official languages in the EU and shall include: 1. Description of the design and manufacture 2. List of components and materials 3. Safety data sheets 4. Safety assessments 5. Conformity assessment procedure 6. EC declaration of conformity 7. Addresses of manufacture and storage 8. Documents submitted to a Notified Body 9. Test reports 10. Conformity of series production details 11. EC-type examination details 12. Conformity of series production details Today, many manufacturers, importers and retailers are still operating on outdated systems like collecting multiple spreadsheets and files, leading to unreliable data and outdated documentation, which creates an almost insurmountable task of trying to accurately trace and maintain the information for each product reference. API’s Technical Compliance File (TCF) solution is a one process procedure that consists of 5 steps to ensure total product compliance: 1. Expert intervention to define the scope of compliance 2. Document collection 3. Document review 4. TCF report issuance 5. Record keeping and database integration (all available online 24/7)
A solution like this promises increased visibility and transparency into your supply chain that will prove invaluable to optimizing your current quality systems, allowing you the time to mitigate any potential quality risks as and when they become apparent.

5. Monitoring Production Consistency With DUPRO/Inline Inspection

The production line is inspected when at least 25% of the order has been completed. The DUPRO verifies that initial discrepancies found out during an Initial Production Check (IPC) have been rectified.

Each stage of the assembly process will be analysed and samples of the goods in progress will be collected and checked. This means that any impending problem can be identified on-site and addressed at the very stage where it is occurring. By checking unfinished products during production and assessing if AQL standards are being met, API assures that corrective actions can be taken in order to assure the quality of your toys moving forward.

6. Checking and Classifying Non-Conformities Right Before Shipping

API conduct both Final Random Inspections and Loading Check inspections to ensure your products conform and that they are being shipped in a safe and secure manner.

Final Random Inspection

A FRI (Final Random Inspection) is basically an acceptance sampling inspection performed prior to shipment. The Sampling is derived from the inspection level requested in accordance with MIL-STD-105E (ISO2859-1). API is also certified HKIAS which endorses third-party inspection based on an in-house procedure. The sampled goods are then checked piece by piece and the non-conformities found, if any, will be classified into three categories (critical, major and minor). The selection of an AQL (Acceptable Quality Level) per type of non-conformities will determine the acceptance or rejection of the goods.

Sample Collection For Lab Testing

Products randomly picked from mass production for pre-shipment testing which can occur in DuPro or FRI. The test checks the alignment of product quality from mass production and pre-production.

Pre-shipment Testing

The aim of pre-shipment testing is to verify the consistency of the production quality with a focus on critical aspects of the toys, without having to perform the full test again. API provides tailor-made testing solutions based on client requirements to ensure quality is maintained at this stage of the process. Loading check inspections to ensure toy quality

Loading Check Inspections

The loading check serves as a way to control container quantity and to adequately manage stuffing arrangement. API performs inspections of packed goods as they are being loaded into the shipping container to ensure the correct products are loaded, in a secure and safe manner.

7. Taking Quality Assurance Full Cycle With Reorders and Random Sampling

Sample collection for testing during the reorder process is a concept of a highly effective continuous quality improvement monitoring program, helping you determine the frequency of testing per supplier performance. This policy sends a clear message to suppliers that you’re watching their product quality closely, and that any unauthorized product/material change is strictly prohibited, and at the same time encourages them to improve.

8. Business Intelligence Tools

In order to the determine the frequency of sampling per factory, you’ll need a comprehensive vendor scorecard. API have developed its own platform for you that records quality data of each factory’s test and defect levels during inspection.

It also provides you with a comprehensive data analysis on factory performance across your own suppliers and across others in our database that you may not currently be working with. The database record does not simply include just the pass or failure of the product test/ inspection, but also a record and classification of each defect. Through this database we’re able to point out top defects recorded per factory and compare your own suppliers against others in the industry.
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REACH – Extension of Phthalates Requirements (Entry 51)

As per the European Union additions published in December 2018, the scope of Entry 51 of Annex XVII to REACH Regulation (EC) No 1907/2006 has some changes starting on 7th July 2020. The changes include an increase in the number of restricted phthalates from three to four, and an extension of the scope of restrictions as per below:

 

Restricted Substances

Scope of Restriction

Current Entry 51

DEHP, DBP and BBP:
≤ 0.1% by weight of the plasticized material (individually or in combination)

Plasticized materials in toys and childcare articles

Revised Entry 51 as of 7th July 2020

DEHP, DBP, BBP and DIBP: <0.1% by weight of plasticized material (individually or in combination)

All articles containing plasticized materials*

What are plasticized materials?

  • Polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyvinyl acetate (PVA), polyurethanes
  • Any other polymer except silicone rubber and natural latex coatings
  • Surface coatings, non-slip coatings, finishes, decals, printed designs
  • Adhesives, sealants, paints, and inks

DIBP was frequently used as a replacement for DBP for lots of plasticized materials. With the new restrictions in place, manufacturers will need to look for alternative options to comply with the normative.

What are the main product types affected by the extension?

With the extension of phthalates requirements (entry 51), all articles containing plasticized materials* will be affected.

These can include:

  • Indoor and outdoor furniture
  • Decoration articles
  • DIY items
  • Office supplies and equipment
  • Bathroom supplies and equipment
  • Accessories, gifts and premium items
  • And more.

*Exemptions

(As included in Annex XVII to REACH – Conditions of Restriction)

(a) articles exclusively for industrial or agricultural use, or for use exclusively in the open

air, provided that no plasticised material comes into contact with human mucous

membranes or into prolonged contact with human skin;

(b) aircraft, placed on the market before 7 January 2024, or articles, whenever placed on

the market, for use exclusively in the maintenance or repair of those aircraft, where those

articles are essential for the safety and airworthiness of the aircraft;

(c) motor vehicles within the scope of Directive 2007/46/EC, placed on the market before 7

January 2024, or articles, whenever placed on the market, for use exclusively in the

maintenance or repair of those vehicles, where the vehicles cannot function as intended

without those articles;

(d) articles placed on the market before 7 July 2020;

(e) measuring devices for laboratory use, or parts thereof;

(f) materials and articles intended to come into contact with food within the scope of

Regulation (EC) No 1935/2004 or Commission Regulation (EU) No 10/20111;

(g) medical devices within the scope of Directives 90/385/EEC, 93/42/EEC or 98/79/EC, or

parts thereof;

(h) electrical and electronic equipment within the scope of Directive 2011/65/EU;

(i) the immediate packaging of medicinal products within the scope of Regulation (EC) No

726/2004, Directive 2001/82/EC or Directive 2001/83/EC;

(j) toys and childcare articles covered by paragraphs 1 or 2.

Do you have any questions about how this extension will impact your products?

With the new restrictions in place, brands, retailers and manufacturers must ensure that the products placed in the market do not contain any of the restricted substances. At API, we can provide technical advice and adapted chemical product testing for your affected product categories to ensure your products comply with the new REACH requirements. Our combined expertise in chemistry x manufacturing x household goods and toys allows our experts to provide tailor-made solutions suited to your needs.

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