First-piece approval checklist: colour samples for colour accuracy, structural samples for functionality, and signed samples for compliance with specifications — by clearly defining ‘what needs to be approved and who has the final say’, rework on the main production run can be avoided.
What should be approved first? The scope of the first-piece approval: colour samples (print colours), construction samples (finished structure), and process samples (foil stamping / UV coating); first distinguish between ‘approval purposes’ (sign-off samples) and ‘inspection purposes’ (trial fitting) before establishing the process — sign-off samples set the standard, whilst inspection identifies issues.
How should approved samples be managed? Approved samples (final samples): two copies (one retained by the factory, one by the client), signed to confirm the version; any ‘revision’ (re-signing) must be updated. The management of approved samples is governed by the principle that ‘the signature takes precedence’.
How should process samples be verified? Process samples (foil stamping, UV coating): positioning (precise alignment), effect (uniform brightness); ‘Abrasion resistance’ (scratch test) must be verified first. Details of the process samples must adhere to the design draft.
How should colour samples be verified? Colour samples (print colour matching): spot colours (Pantone numbers), four-colour process (colour difference values); verification must be carried out under ‘standard lighting’ (standard light source), with shade depth determined by the approved sample. The verification of colour samples is governed by the principle of ‘what you see is what you get’.
How should structural samples be verified? Structural samples (moulding): box type (smooth opening and closing), dimensions (fits inside); “test assembly” (inserting the product into the box) to confirm tightness and the positioning of internal inserts. The inspection of structural samples is based on the principle of “fits in, comes out”.
First-piece approval serves as the ‘final check’ before mass production: even a slight colour discrepancy or a slightly loose fit will be too late to rectify once the bulk production run has commenced — a lack of thoroughness in first-piece approval determines the quality of the entire batch. This article clearly outlines the key points of first-piece approval; clients commissioning custom packaging should refer to it as required.
