A few years ago I wrote about the inspection levels, but I regularly notice that some people are confused about the "special" levels (S1, S2, S3, and S4). Here is what the ISO 2859-1 standard says (emphasis is mine): The inspection level designates the relative amount of inspection. Three inspection levels, I, II and III, are given in Table 1 for general use. Unless otherwise specified, level II shall be used. Level I may be used when less discrimination is needed or level III when greater … [Read more...]
When To Do a Random AQL Inspection vs. Check 100% of the Goods
First, let me get one thing out of the way: not all batches need to be checked. If a manufacturer has great systems and processes, and if they have a history of complying with your quality standard, there is usually no reason to send quality inspectors to their facility. Similarly, if you can easily return the whole batch and it can be reworked quickly, you probably don't want to spend resources on checking whether they did as promised. Now, let's assume you do want confirmation of … [Read more...]
Sourcing Trends in 2019 between China and other Asian Countries
I attended the Made in Asia conference last week, and the opening talk was given by Ben Simpfendorfer (Founder & CEO at Silk Road Associates, a strategic advisory firm based in Hong Kong). Ben is one of the most insightful people I know when it comes to covering sourcing trends in China and other Asian countries. Here are some of the interesting points he mentioned. The market shares of different Asian countries (Vietnam, Bangladesh, Indonesia, India...) haven't been changing as … [Read more...]
The Problem With Visual Management Boards in Factories
Visual management boards of some kind are now basically the norm in all factories belonging to a multinational group, so they must be effective, right? I'm not so sure. Not that they cannot be useful (they CAN be VERY useful), but, in most cases I have witnessed, these boards just aren't contributing as much to lean initiatives or process improvement as factory management would like them to be. … [Read more...]
QC Basics: What is a Quality Inspection? Context, Tools & Template
This article describes what a quality inspection is, and when it typically takes place (before, during, and after production). We will cover the types of inspections most widely used by buyers in international trade. They should be performed by 3rd party QC providers (appointed by the buyer), or by the buyer's own inspectors, if you buy from China, Vietnam, India, or another low-cost country. … [Read more...]
How To Keep A Clean Factory And Stop Dust On A Budget
In many industries, one of the most common reasons for defective goods is dust contamination, and they have adopted different cleanliness standards (see the Wikipedia page on cleanrooms and factory cleanliness). If you have visited Chinese factories in certain industries, you have probably seen their efforts in that regard. During our factory audits, we always give a grade about general organization and cleanliness. What advice can I offer about maintaining a clean factory without spending … [Read more...]
3 Common Ways Factories Try to Cheat Inspectors/Auditors
Every day in China, in Vietnam, in Bangladesh, and in India, thousands of inspectors and auditors take a bus or a car to a factory. And, in some of those factories, managers are plotting how to cheat those unwelcome visitors. Let's look at 3 very common ways this is done, so you are warned and ready to avoid unscrupulous suppliers like this... … [Read more...]
Some Problems Can’t Be Detected During Apparel QC Inspections
A few years ago, I wrote about the limits of random quality inspections. My focus in that article was on the random elements, on human mistakes, and on the tricks that manufacturers can play. Today I'd like to write about issues that simply can't be detected during inspections, even if 100% of the goods are checked and inspectors do a perfect job. I will write about a product line that I know well: apparel. … [Read more...]
Actionable Tips To Improve Sourcing From China & Develop Suppliers
Over the years, many importers have contacted me after making various mistakes, and, often, the best they can do is start things over with a new supplier, but that means a lot of wasted time, money, and energy! What if you could get years of advice about sourcing from China and developing suppliers once you've started working with them in order to avoid this scenario, but distilled into one eBook? Now you can! A few years ago, I wrote 15 articles that address sourcing from China and … [Read more...]
Are Your Chinese Factory’s Batteries Made by Samsung, LG, or Panasonic?
Let’s say you buy an electrical product that is assembled by your Chinese supplier and they promise to purchase original batteries from a well-known company. Are you sure you will get what you pay for? For the buyer, the question becomes: "How to ensure our batteries are really made by Samsung, LG, or Panasonic?" … [Read more...]