Seirial 1: How to solve supplier quality problem? What QC is the best QC?

Seirial 1: How to solve supplier quality problem? What QC is the best QC?

The most common complaints about doing business are probably products quality. Whether the product quality or packaging problem. And the most amazing thing is that you never know what problems the factory will give you. Maybe today is the raw material, tomorrow is the semi-finished product, the day after tomorrow is the packaging… It is absolutely ever-changing and shocking.

No.1: Summarize the quality headache most commonly with China exporter

If you run into a boss who will shirk all responsibility to the salesman, it will be even worse!

Take an example, you placed an order of stamping parts or Deep drawing or sheet metal components to China factory or trader.

But finally, you found the quality of the stamping parts is very poor after 2 months waited when all these stamping parts arrived at your location.

You may be angry and said:

“What did you(salesman) doing, you don’t know to go to the factory and inspect the quality of the goods?”

He(salesman) may think in heart: How it possible that I check the goods one box by one? 

Or you found the stamping parts raw materials was wrong(after all products have been finished).

You began words again:

“Why didn’t you find out the problem? Why not keep following up the order?”

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No.2: dissection what reasons result in these supplier quality problems – Chapter 01?

Maybe your salesman just a beautiful girl, and she is discussing with you on Skype or Whatsapp frequently. In fact, she may just graduates from university 2 years ago and does not know how her factory produced these products. Or all she got an answer by asking an engineer or manager.

Mostly they will think like:
-All the problems with your raw materials are my wrong? Do you want me to stay in the factory all the time? Why not change the factory manager and let me take place?

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No.3: Summarize the quality headache most commonly with China exporter – Chapter 02

The much worse thing is your another China metal stamping parts manufacturerpackaging is wrong, you will blame them why just packing can’t do it as your requirement:

“What do the salesmen do?You don’t know you need to carefully check the draft before printing?”
– Oh My God, before the painting I gave you drawing to confirmed, ok???

All these, I think you will want to have more middle fingers to point out:
“Fuck! What the hell are you talking about?!”

For this kind of trading companies or factories in China, their best dream is that every order is shipped smoothly, and the money is also taken smoothly, perfect without problems.

As for delivery, price, and all external conditions, they can use their tongue to talk to customers. Or a beautiful face acting cute at your face, maybe you will forgive her…….HAHA

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However, these China factories(automotive stamping parts) or trading companies often have problems.

No.4. If there any way to solve these quality problems?

If there any way to solve these problems?
-Of course, even the best quality control will inevitably lead to some problems. But our requirements may not so high, and occasionally some small problem can be acceptable.

So, we will have a good chat about quality control QC today.

QC, is quality control. In the impression of most China trading companies and factories, it may only mean inspection: After order was finished 80% before packing of the goods, then a random inspection is carried out (according to the sampling basis and the standard to make a whole batch of goods), Usually we call AQL1.5/4.0 is such a sampling standard.

The following figure is a standard Table of AQL:

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Use the first sampling plan below the arrow.  If sample size equals or exceeds lot or batch size, do 100% inspection.

No.5 Except for ISO 9001 certification, the China factory how to control product quality in reality

In fact, in the actual operation process, whether it is a China trading company or a factory, and whether a customer or a third-party inspection company, it is difficult to strictly follow such a standard inspection standard. This means that to do such quality control inspection most times is not validation.

What reasons?

You will say: every China factory or trading company are confirmed with you they will strictly check the goods dimensions 100% according to AQL1.5/4.0 and ISO9001 certification.

Strictly speaking, AQL 1.5/4.0 must be based on the randomization of all goods. However, when actually inspect the goods, we will find that the place and the goods are stacked often only allow us to check the upper of the surface. It is means: only the goods which stacked on the racks can be controlled.

Maybe you still not believe me what I said, please see the following pictures:(you can only check the top floor goods rather than those in the center or bottom)

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These pictures are roughly described most of China factories how they stocked their parts today.

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No.5.1 Why you can’t check the inside boxes?

  1. no one will help you remove the upper and outer boxes.
  2. no place for you to put the box moved down.

This means that we don’t have enough checking numbers to guarantee the validity of this checking report. So, for importers who hope to ensure quality control and shipment safety through this method, you can give up!

No.5.2 So, how to do a good QC for production?

Let’s first set aside the definition of ISO. And recall how our quality control is:

Probably every China salesman has been suffered quality complaints.

When the customer send a complaint to a China factory or Trader, although your China supplier will clearly reply you, and observe the requirements of your drawings and strengthen the prevention, even filled the 8D report as you asked. But after a few months, the problem happened again. What the fact?

No.5.3 Most of them are going through the game for QC.

Where are the quality problems: The production factory and the sales manager are always disputed with each other? Even many factories will say to your representative (China trading company) “you have already checked the goods before shipment, how do you blame me for quality problems?” In other words, even if the factory acknowledges the quality problem, it is impossible to replace your bad parts which have arrived at your location.

No.5.5 In the reply, most of your China factory or trading company are like this:

  • Probably the workers picked the wrong one
  • Probably the machine is not adjusted
  • Probably the packaging worker was careless to see
  • Probably negligent when testing
  • ……

Some better China trader or factory even after making compensation, replenishment or various amendments, but many of them also still have problems of one kind or another next time.

No.5.6 What makes our quality control so bad?

In addition to human beings not paying attention to it, we have not established a complete quality control system in the company and the factory. The so-called ISO9001 AND IATF certificates are just a piece of waste paper which made by the surface work.

This is also the specific performance of many China factories that lack overall responsibility. Maybe not only China factories or trading companies have this performance, maybe all countries have same problems.

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No.6 Summary of the quality problem reasons with manufactures

It is not easy for a salesman to make an order,  find a customer, fight for a price, and fight for a machine.

However, many salesmen spent 50%-70% of their time to manage their China factory or trading companies QC problems, handling various complaints and supervising the quality of the production line. This is obviously a waste of energy and time.

The true QC is the entire production process from the raw material income to final finished product inspection and goods delivery.
For a company, it is not difficult to establish a system of quality management.

But why this is still a long-term heart disease for China factories and traders?
The reason is very simple -No responsibility: As long as there has money to earn, they will dare to produce and sell, and care little about the safety of consumers. In addition, the legal system is not perfect, there will always be opportunities for them to find holes.

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No.7 Classic case about the manufacture quality control – USA food factory

Everyone knows that the inspection of beef in the United States is very strict. I remembered that there was a TV show called “food factory”:

Whether American beef is made into other foods or fresh beef in the supermarket, it can be traced directly to the time when the little cowboy was born. When the little cowboy was born, he will be labeled with an electronic label after quarantined. The little cowboy’s dad and mom’s info will also record, including how to raise, whether have been vaccinated, whether they are sick or not. Before put them into the slaughter house, the entire information will be got from the label. At the time of the acquisition, professional personnel is hired to check whether the cow meets the food standard.

The slaughter house will be sampled and tested after the slaughter. After the testing passed the standard, then it can be sent to the split line for the division. The package also should be tested whether reasonable and the storage if proper. According to the standard, the meat temperature must be kept from 0℃ to 5℃ to ensure the freshness and to avoid the possibility of deterioration. When it comes to the next step, both transportation and reception need to be inspected at any time. The product can be sold only if the inspection is acceptable.

If consumers encounter product quality problems, they can use electronic information to investigate specific problems, obtain huge compensation and correct them to avoid more problems.

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