Controlled shipping is a containment your customer imposes after a quality escape. CS1 is a redundant inspection you run yourself, separate from and on top of your normal checks, at your own cost. CS2 adds an independent third-party inspection on top of CS1, when the customer wants outside verification rather than your word that the problem is contained. Neither level ends until you meet the customer's written exit criteria.
If one of your customers has placed you on controlled shipping, you already know it is not good news. It usually follows a quality escape, and it signals that your customer no longer trusts your normal process to catch the problem. Until you satisfy their exit criteria, every shipment you send carries extra cost and extra scrutiny.
This guide explains what controlled shipping is, the difference between CS1 and CS2, what it costs you, and how to get back to normal as quickly as possible.
What controlled shipping is
Controlled shipping is a containment process a customer imposes on a supplier after a quality problem. It requires you to add inspection beyond your normal process to guarantee that no defective parts reach the customer while the root cause is being resolved. You certify the good stock, document everything, and report the results to your customer on a defined schedule.
It is not a permanent state. It is meant to protect the customer's line while you prove your process is back under control, and it ends when you meet the customer's exit criteria.
CS1: Controlled Shipping Level 1
Controlled Shipping Level 1 is the first step. You put a redundant, dedicated inspection in place, separate from your normal quality checks, to contain the specific defect your customer is concerned about. You run this containment with your own resources or a partner, at your own cost, and you keep clear records of what was inspected, what was found, and what shipped as certified good.
The goal of CS1 is simple: make absolutely sure the defect cannot reach your customer while you work the root cause and corrective action.
CS2: Controlled Shipping Level 2
Controlled Shipping Level 2 is added when CS1 is not enough, either because the problem continues, the corrective action is not yet effective, or the customer wants stronger assurance. CS2 layers an independent third-party inspection on top of your CS1 activity. The third party performs a separate, redundant containment, so there are now two independent checks standing between the defect and your customer.
CS2 raises the cost and the visibility. It is a clear signal from your customer that they want outside verification, not just your word, that the problem is contained.
How CS1 and CS2 differ
The simplest way to think about it: CS1 is your containment. CS2 adds an independent one on top. CS1 can be run internally; CS2 specifically requires a third party your customer will trust. Requirements vary by customer, so always work to your specific customer's controlled shipping instructions.
What controlled shipping costs you
The inspection labor is only part of it. Controlled shipping also costs you management time, reporting effort, and, most of all, standing with your customer. The longer you stay on it, the more it signals risk. That is why the real objective is not just to comply, it is to exit cleanly and quickly.
How to exit faster
Getting out of controlled shipping comes down to two things: airtight containment so no new defects escape, and a corrective action your customer accepts. Most exit criteria require a defined number of clean shipments or clean days with zero escapes, plus customer sign-off on your root cause and corrective action.
A dedicated, independent containment helps on both fronts. It keeps escapes at zero while you fix the process, and, when a third party runs it, it satisfies the CS2 requirement and gives your customer the outside assurance they are asking for. PLI provides exactly this kind of rapid containment support, including CS1 and CS2, for automotive suppliers under customer pressure, and can often coordinate support within 24 hours when the clock is already running.
Facing a controlled shipping situation? PLI can put an independent containment in place fast. Request immediate support or call 216.440.6060, 24/7.
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