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amarpreet41
- November 22, 2025
Last month, one of our customer a Bangalore based electronics product manufacturer was ordering a batch of 500 PCBAs from a supplier in Ahmedabd. The delivery was critical – they had a deadline to meet for their defense customer and any delay would mean penalties.
They contacted us at Zenaca Consulting to do a pre-shipment inspection before the supplier ships the goods.
Here’s what we found:
Out of the 500 PCBAs inspected, we identified 38 boards with soldering defects (cold joints, bridging) and 23 boards with wrong component placements. That’s over 7% rejection rate!
If these boards had been shipped without inspection, here’s what would have happened:
- Customer would receive defective boards after 3-4 days
- They would need to send them back to supplier
- Supplier would need to rework or manufacture fresh boards
- Another 7-10 days delay minimum
- Total time lost: 2-3 weeks
- Additional cost: ₹2.5 lakhs (rework + logistics + penalties from their customer)
What Actually Happened:
Our inspection report was shared within 24 hours. The supplier immediately started rework on the defective pieces. Within 3 days, all 500 boards were ready and shipped – meeting the original timeline. Our team also worked with supplier on setting up their SMT processes, so that they doesnt’ produce these defects again.
Total savings for Supplier and customer
- Time saved: 2+ weeks
- Money saved: ₹2.5 lakhs
- Customer relationship: Protected
- Reputation: Maintained
Another Quick Example:
An Israel based company was importing Hard Cases from a vendor in Coimbatore. We did inspection and found that 15% parts were outside tolerance limits. Catching this early saved them from:
- Rejections at incoming inspection
- Production line stoppage
- Emergency air freight costs for replacement parts
- Estimated savings: ₹4 lakhs and 10 days
Why Pre-Shipment Inspection Works:
The logic is very simple. It’s much easier and cheaper to fix problems at supplier’s factory than after the goods have traveled 1000s of kilometers to your warehouse.
At Zenaca Consulting, we’ve helped dozen of customers across India save both time and money through our independent inspection services. Whether it’s PCBAs, wire harnesses, CNC components, or sheet metal parts – catching defects before shipment is always the smartest decision.
For every ₹1 spent on inspection, our customers typically save ₹10-15 in avoided costs.
Interested to know more? Drop a comment or DM me. Happy to share how we can help your business too.
#QualityControl #Manufacturing #SupplyChain #MakeInIndia #InspectionServices #DefenseManufacturing #ElectronicsManufacturing