chineese quality assurance how is it done

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Chinese Quality Chinese Quality Production Production assurance assurance Joel Mandel May 2012

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Page 1: Chineese quality assurance how is it done

Chinese Quality Chinese Quality ProductionProduction assurance assurance

Joel MandelMay 2012

Page 2: Chineese quality assurance how is it done

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Objective: Taming

the Giant Panda

Page 3: Chineese quality assurance how is it done

Problem Analysis

• Low volume high mix has been for many years been the reason why many Israeli manufacturers dread the Chinese

market.

• Due to the increase competition and cost reduction has forced us to produce in the far east. This drive has required

a need of for a different kind inspection in China

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Page 4: Chineese quality assurance how is it done

Methodology

Major emphasis on quality source inspection in china For the following reasons:1. Quality assurance production representation which

gives immediate response to manufacturing problems: 1. minimizing influence on scheduling.2. Gives option to stop production in china on-line

and rework or new production. 2. Education – To educated the Chinese companies

that it does not pay to give us poor quality.3. Ensure drop shipment quality.4. Minimize quality cost.

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Page 5: Chineese quality assurance how is it done

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Chinese Quality

Inspection production Overview

Production Readiness \Audit (PRA)

Production Final Inspection

Company Manufacturing/ Audit( ISO compliance)

Production In-Line Inspection

Page 6: Chineese quality assurance how is it done

• The first stage in approving a manufacturer is to audit the company . This is a process where you evaluate the manufacturer as to his capabilities to produce your product and complying with ISO 9000. In many companies this is done by management.

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Company Manufacturing/ Audit ISO compliance

Page 7: Chineese quality assurance how is it done

Production Readiness Audit

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PRA is an inspection audit who’s goals are as follow:

1.To verify that since the Company audit nothing has changed. Subcontractors were not changed and if changed to verify the compliance of the subcontractors to the requirements

2.To verify that raw materials comply with all product requirements.

3.The production file is updated and all corrective action if any were implemented from last production and implemented in the production file/line.

4.Test stations are calibrated and manpower is certified.

Note :The Chinese market is always looking to reduce cost and the best way is with raw materials which influence the reliability (long term) and not the quality (short term). In addition since time period between production is notcontinuous . It should be assumed that it’s a new production. Manpower in china changes frequently especially after their yearly vacation and this causes a direct effect on the quality of the production and quality and reliability of the product .

Page 8: Chineese quality assurance how is it done

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Production In-Line Inspection(PIL)

The Production In Line Inspection goal is :

1. to spot check of functionality (short circuit, open circuit etc ) per product specifications.

2. Inspect quality of workers and work flow process on the production line.

3. Initial data yield analysis

Page 9: Chineese quality assurance how is it done

Production Final Inspection

• PFI- Production final inspection is the last stage where poor quality can be blocked.

• The goal of this stage:– Is to verify the compatibility of the purchase order to the production

batch (quantity, catalogue, address etc) and to the packaging specifications.

– Sampling of the production batch .

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Page 10: Chineese quality assurance how is it done

Overcoming the culture& language

barrier. How is it done?

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Tencent QQ

+ +

OutstandingQuality

Real Time /On Line Source Inspection

Page 11: Chineese quality assurance how is it done

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Quality Manufacturer Audit

Production In source inspection

(

Passed

Inspection

Production Readiness Audit

Shipment supplied

Passed

Inspection

?

Final Inspection

Immediate repair & corrective all batch

?

?

?

PRA passed Inspection

?PRA passed

last Inspection?

First production day 100% inspection passed

MIddle day of production 50 % inspection. pass

Final production day 50 % inspection pass

?

?

every Pallet 2 products/cartons are checked

?

Increase sample by double sample

Check pallet with failure 100%

Management reject descition

Immediate repair & corrective all batch

Immediate repair & corrective all batch

Immediate repair & on pallet

First production day

100% inspection passed

Final production day 50 % inspection pass

Production

In source

inspection

Final Inspection

Shipment supplied

every Pallet 2 products/cartons are checked

Express lane after 5

successful failure-free

productions