Toys & Juvenile — Pre-Shipment Inspection Report Template
The full checkpoint checklist for a pre-shipment inspection of toys and juvenile products — safety-critical checkpoints, small parts and sharp edges, labelling and age-grading — structured to ANSI/ASQ Z1.4 (ISO 2859-1) sampling, with AQL defect classification built in. Read the full checklist below, or download the editable Word version to use on your next shipment.
Get the editable template
The full report as a fillable Word document — sections, checkpoints, sampling tables and defect log ready to use. Free.
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What this template covers
Every toys & juvenile PSI report is graded across nine result criteria. The inspector records a result and note for each, and the overall lot is judged Pass / Pending / Fail against the AQL.
Sampling & AQL
The template samples to ANSI/ASQ Z1.4 (ISO 2859-1), with separate sample sizes for visual & workmanship, functional tests and special checks. Defects are recorded against the accept/reject numbers for your chosen AQL and inspection level. Need the numbers? Use the free AQL Sample Size Calculator.
Critical
May harm the user or breach mandatory regulations. Accept number is 0 — a single critical defect fails the lot.
Major
Reduces usability or salability; likely to cause customer returns. Judged against the major AQL (commonly 2.5).
Minor
A deviation unlikely to reduce usability or salability. Judged against the minor AQL (commonly 4.0).
The full inspection checklist
Every checkpoint the report walks through, in order. Each is scored at your chosen inspection level and recorded with photo evidence. Not every checkpoint applies to every product — delete any that don't fit yours when you edit the template.
Package & Packaging
Packing method and conditions / Retail package artworks / Correct content within the package / Quantity of items & accessories within the package / Presence of correct version of printed literature within the package
Conform with client specifications / Shipping marks / labels and their position
All the barcodes need to be clean / Barcode type as requested / Positions as per client requirements
Check the individual packaging (poly bag / wrap / box) protects the product from scratches, marks and transit damage.
Verify carton board strength (burst/edge crush) suitable for part weight, proper taping/sealing pattern
Style / Construction
Same style/materials with approved sample.
Same style/materials with technical file of the client.
Confirm materials match the approved specification / sample (visual and hand check; supplier CoA or certificate where applicable).
Logo, Labelling & Markings
Logo quality, colors, dimensions, positioning, and alignment must conform with client specifications.
Correct content within the label & marking.
All the barcodes need to be clean. / Barcode type as requested. / Positions as per client requirements.
Confirm the safety/warning labels required for the product and destination market are present, correct and legible.
Verify age-grade marking and choking-hazard warnings match the destination market / (EN 71 / ASTM F963 / 16 CFR 1500).
Accessories
Accessories (if any) / Instruction Literature (if any)
Functional & Performance
Weight shall match the product specification / approved sample. / Unless otherwise specified, tolerance ±5 %.
One column of export carton will be piled up to a height of 2.5m or as intended to be palletized for four hours. After the test, the bottom carton must show no compression that would affect the carton's shape and no damage to the product inside.
Height and drop sequence according to ISTA 1A procedure. Freefall on hard floor on one corner, three (3) edges, six (6) faces from ..... cm.
Operate each function as intended for use / The product needs to function in compliance with the information provided.
Operate functional and adjustable parts (if applicable), 20 times. Functions shall respond properly; no damages or blocked function shall occur.
Pull test on small parts and accessories. / Use a pull gauge, 70 N for 5 s (children's products per EN 71 / ASTM F963). / If no gauge is available during inspection, check by hand with appropriate force.
Apply 3M-type tape over the printing/screening and pull off at a 45° angle. / Markings must remain clearly legible; adhesive labels must not work loose or curl at the edges.
Rub the item 10 times over a 10 cm distance with a force of 9N (1kg). / There should be no color transfer greater than 4 on a grey scale (between the original white cloth and the colored one) after the dry test. / There should be no color transfer greater than 3-4 on a grey scale (between the original white cloth and the colored one) after the wet test.
Check the smell of the product. It should not have any solvent, mould or strong odor.
All the barcodes need to be clean and readable with a barcode reader and the reading must correspond to client's information and printed numbers / characters. / Barcode type as requested. / Positions as per client requirements
Test small components in the small-parts cylinder (EN 71-1 / ASTM F963). / No component for the stated age grade may fit entirely in the cylinder.
Check all accessible edges and points (EN 71-1 / 16 CFR 1500.48-49). / No accessible sharp edges or points allowed.
If applicable: charge samples until full — no interruption or abnormal heating; record the full-charge time. / Discharge in continuous use and record the runtime.
Once per lot: review the toy safety test reports / certificates (EN 71, ASTM F963, CPC) as requested by the client.
Apply the standard torque and tension to projecting components (EN 71-1 / ASTM F963). / No release of small parts allowed.
Other (Client) Specifications / Requirements
Workmanship
Product physical conditions, appearance & cleanliness
Inspect for burrs, flash, sharp edges, scratches, dents, or discoloration on visible/functional surfaces
Inspection conditions & site observations
A complete report also records the conditions under which the inspection was carried out — because a clean checklist means little if the sampling wasn't trustworthy:
How to use this template
Set your AQL and inspection level, then fill the report as you inspect. The defect log tallies critical / major / minor against the accept/reject numbers so the Pass / Pending / Fail decision is objective. Attach photos to each section.
Download the editable template
The full report as a fillable Word document — sections, checkpoints, sampling tables and defect log ready to use. Free.
Word (.docx) · Free · No watermark
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