A product failure analysis is an activity manufacturers hope they'll NEVER need to do. If something has gone wrong enough to warrant doing one, you're probably experiencing product quality or safety issues that are so severe that customers are returning them in numbers, or even, at the extreme end of the scale, getting hurt! If you are hit with quality, reliability, or safety problems with your product during development or, more likely, in the field, it may be necessary to help you … [Read more...]
Want To Prevent Assembly Problems? Use This Checklist.
Pilots follow a checklist before they fly. Same thing for doctors & nurses. But, for some reason, I see very few Chinese factories follow a checklist that can help them avoid assembly problems before they make a new product (for the first time). I jotted down some important points any assembly factory should confirm before production begins in order to avoid assembly problems. (It is not very different from the points we typically check in a 'production readiness audit' for an … [Read more...]
An Introduction to Root Cause Analysis (Not Just for Manufacturing)
One of the most frustrating aspects of working with Chinese suppliers is that, for the most part, they don't want to (or cannot) conduct a root cause analysis. Let's say you found a serious issue in one of your productions and you don't want it to come back in the future. You ask for an investigation into that problem. And they come back with very superficial responses that are clearly still far from exposing root causes. Here are very common excuses: "It is due to an issue on the … [Read more...]
Fixing Problems at the Root: ‘Upstream Thinking’
I have been enjoying the book Upstream: The Quest to Solve Problems Before They Happen by Dan Heath. It is not really a business book, as it covers many examples outside of business, but it does a great job of arguing in favor addressing problems at the root cause level. … [Read more...]