I see buyers who spend a lot of time pushing their suppliers to do QC inspections on incoming components, to keep the production area clean, to give clear instructions to operators, and other basics. But I seldom hear them push for traceability in manufacturing, despite how important it is. I thought I should write about it again. … [Read more...]
Managing QC Inspectors, Part 8: QC vs. QA
This is the eighth part in the series about the management of QC inspectors in China. Different companies give different job descriptions to their inspectors. I don't think there are "best practices" here, but this is an important topic and I want to cover it. The primary role of a QC inspector Inspectors should collect and report information. They should not take decisions, in order to reduce risks of bribery. Similarly, they should not try to solve the problem with the factory. The … [Read more...]
Managing QC Inspectors, Part 7: The Quality Manager in China
This is the seventh part in the series I am writing about the management of QC inspectors in China. Many companies in China have difficulties finding the right quality manager. In particular, it is difficult to find an individual who will simultaneously: Run the day-to-day operations of the quality department and repeat the same principles to his staff and to suppliers 10 times a day -- and keep doing this for years; Be a change agent and guide his/her team to work in a different way (from … [Read more...]
Managing QC Inspectors, Part 6: Planning the Inspections
This is the sixth part in the series about the management of QC inspectors in China. In my last article on this topic, I mentioned the need to have system to manage the planning. Some companies let factories and inspectors set the planning freely among themselves, and I think that's a big mistake. Here is the advice I usually give buying offices. 1. Manage the planning in the office An assistant manager should set the planning. Suppliers should send an application (for example every … [Read more...]
Managing QC Inspectors, Part 5: Avoiding Bribery
This is the fifth part in the series about the management of QC inspectors in China. I touched on the evaluation of quality inspectors, and it naturally brings up the topic of bribery. How big of a problem is corruption of inspectors in China? In many developing countries, people in a position of authority, and to a lesser degree those who report information for use by decision makers, are prone to corruption. It happens in Mexico, in China, in Bangladesh, in Egypt, and in many other … [Read more...]
Managing QC Inspectors, Part 4: Evaluating their Performance
This is the fourth part in the series about the management of QC inspectors in China. Let's say you have hired the right profile, you have given them the right equipment and the right checklist, and you have provided them with the right mix of training and coaching. You need a method to evaluate their performance in order to know who should receive a bonus and/or a raise... and who should be let go. 1. Defining expectations clearly You can't hire Chinese inspectors if you don't have a … [Read more...]
Managing QC Inspectors, Part 3: Training, Coaching, and Auditing
This is the third part in the series about the management of QC inspectors in China. Let's focus on the activities of training, coaching, and auditing inspectors. A few years ago I listed 7 ways inspectors can fail to notice quality problems, which included 4 issues that good training, coaching, and auditing should mostly eradicate: Laziness and lack of discipline Lack of training Wrong calibration (e.g. the wrong standard is applied) Corruption My point is, you can't skip on … [Read more...]
Managing QC Inspectors, Part 2: Checklist and Equipment
This is the second part in the series about the management of QC inspectors in China. I am looking at two very important parts of the preparation. Common shortcomings Here are a few issues that I often see: A "golden sample" is approved, and it is the only standard to be followed. But a golden sample is not sufficient. It does not include critical information such as the severity of potential defects, how certain tests ought to be conducted, etc. The buyer does not specify what packing … [Read more...]
Managing QC Inspectors, Part 1: The Hiring Process
I am starting a series about the management of QC inspectors in China. Part 1 is about hiring a team of inspectors. I listed before the types of backgrounds of most quality inspectors. But what profiles should you look for, how should you evaluate them, and who should manage them? 1. The psychological profile For simple QC inspectors, it often makes sense to hire young graduates with no experience, to teach them your product requirements, and to ensure they follow the right inspection … [Read more...]
Benefits of quality control inspections
The question is, are inspections useless? What are the benefits of quality control inspections, if any? As I mentioned in a previous article, more and more importers are switching their focus from standard QC inspections to improving key suppliers. My opinion is, there are benefits, but they depend on the kind of inspection. Here is Shingo's typology: #1. "Judgement inspection" (prevents shipment of defective batches) Quantify, and if possible sort out, defects. Takes place … [Read more...]