Ensuring Quality From China and India
Lets assume that you are outsourcing your own production, not trading on a new product. Ideally, you are a manufacturer so in fact you know more about the product than your vendor. So, what steps can you take to a: find a reliable vendor, and b) ensure the vendor delivers the product you need when you need it.
First, recognize that consistent quality, lot after lot, is achieved by very few companies. 6-sigma is a far-reaching and distant target for almost all companies. Accept that there will be orders that go wrong.
Secondly, it's sometimes hard to determine if a bad shipment occurs because of poor production, poor packing, or shipping-related, and it can take time to attribute the cause. So your objective should be to minimize the occurrence of errors, not eliminate them. I know this is an anathema to many quality advocates, but I am only referring to sourcing from developing countries, not Japan, Germany or USA. Reality is that the vast majority of managers in China/India have not been raised with, and thus have no concept of, western quality standards.
The steps I have found work are: develop a company relationship; plant inspections / approvals; raw materials control; product and production controls; product and pre-shipment approval; post-shipment inspections; documentary / payment controls.
1. Company Relationship (China):
a. Establish a relationship with senior management (meals, drinking etc). Establish trust first.
b. Make sure one key senior manager is appointed to be the conduit between your company and theirs. This person must have authority to negotiate both with you and the plant. In many Chinese companies, a VP you work with will likely need to negotiate and cajole the plant's Director to move in a certain direction. Decision making is less solid-line, and more dotted-line.
c. Make sure whomever first meets with the vendor can be credibly, and readily established as a product & market specialist. Be prepared to share enough information with them to make them respect your capabilities in the market. Good Chinese manufacturers take pride in where their products go, and it helps to be able to show them that you have the where with all to market the product well. Be humble, but clear about your capabilities
d. Teach them! If you know how to make the product correctly, show them. Yes, you are giving away your secrets, but if you don't share what you know works and what does not, then the manufacturer can't be blamed if they get it wrong.
e. When you visit the plant, be sure to be given permission to interact with lower level managers. If you have established trust, first, then this will not be an issue. These people will be most important to the quality of your product. Teach them, ask them, show them.
f. Do not impose, or seek, penalties for late deliveries or rejected product. If you start with this, you are stating very clearly that you don't trust the supplier.
g. If possible, have a sourcing team based in China. Not to look over the supplier's shoulders, this just breeds antagonism, but rather to facilitate decision making and training.
2. Company Relationship (India):
a. Try to find a connection to a supplier through your close networks. Ideally, a senior manager at the supplier is connected to you by no more than 3-degrees of separation. In India, this is the best way to establish some sort of relationship that can be somewhat trusting. Ask, and keep the mutual connections in the loop as to the macro-events in your relationship
b. Talk up your capabilities. Do not share too much information on who your customers are. Share information about volumes and growth and vague references to accounts. No need to be too humble. You'll need to impress them to be taken seriously (most Indian companies believe they are awash in orders and opportunities)
c. Teach them! Applies in India as well, but be more guarded as to the conditions under which you reveal processing techniques. There has to be a quid pro quo. Indian companies will very quickly use your skills to market themselves to your accounts, so be careful.
d. When you visit the plant, interact with lower level managers. Seek answers to your questions by first asking open-ended questions, and then a follow-up direct question for confirmation. Don't spend too much time training them. In India, hierarchy matters, so interact with Operations Manager / VP Operations etc, and allow them to delegate down.
e. Do not impose, or seek, penalties for late deliveries or rejected product. It won't matter in India as enforcement is impossible.
f. If possible, have a sourcing team based in India. Not to look over the supplier's shoulders, this just breeds antagonism, but rather to facilitate decision making and training.
3. Plant Selection / Approvals
a. Visit many plants. Take the time for more than one inspection.
b. Look to inspect the second/third shift. If you are a new customer, or have a smaller order, chances are you will be on the later shifts. Many plants employee 2nd-tier staff and labor then
c. Your Plant Manager should be in charge of the appraisal. I've had my customer's marketing department attempt to pass judgment on our plant and its processes. Complete lack of credibility.
d. Pay particular attention to the processes and staff at the plant. Not just the property and equipment.
e. Ask for third-party inspections from respected firms (Bureau Veritas, SGS etc.)
4. Raw materials
Standards for raw materials are critical. This is a frequent cause of product failures when sourcing from China / India. The vendor is forced to use sub-standard raw materials in order to meet shipping deadlines (with the global scarcity of raw materials, in general, there is scant time to wait for new raws).
a. Inspect raw material suppliers! (I spent 9 hours on a train to in-land China in order to inspect a glass supplier - glad I did as it spawned another business)
b. Ask as much of the raw materials as you would of your finished product. Plant certifications, management history etc.
c. Ask for samples of the raw materials that will be used in your production. Have counter-samples signed by all parties and retain a copy by each party (raw supplier, your vendor, you)
d. Ensure your vendor is as vested in raw materials knowledge and expertise as you are. From the Supply Chain manager to the QA Manager to Operations Manager, each of them should be able to tell good raws from bad.
e. QA personnel must be trained to set standards for all raw materials (from packaging to components), and must perform inspections of raws when they arrive at the plant
f. Their Supply Chain Manager has to be someone you are personally in contact with, and with whom you can (and are allowed to) communicate on supply strategies and issues
g. Establish a relationship where your vendor informs you of raw materials issues in order that you can jointly agree to either use the sub-standard raws, or delay product shipment and wait for new raws.
5. Product / Production:
a. Product definition: detail all the specifications for your product. Ideally your product specification should include everything from approved raw material suppliers to processing parameters to cmyk colors of packaging. The document should be signed by both parties, and in particular the QA and QC heads. Some say this risks giving away too much information - but I contend that you can't get what you ask for if you never actually ask for it.
b. Equipment
- Know the shortfalls of various equipment that can be used to make your product
- Educate your vendor on these shortfalls, and help them with work-arounds / compromises
c. Processes
- Know the shortfalls of various processes that can be used to make your product
- Educate your vendor on these shortfalls, and ensure they are not used in your production
d. Price: negotiate fairly from the basis of knowing what the likely manufacturing costs are. Do not low-ball in an attempt to garner higher margins - the days of that game are long gone in both India and China. At the same time, do not believe that higher prices will ensure better quality. Most factories have one set of suppliers, one set of processes, one set of staff -offering higher prices does not change any of that
6. Product Approval / Pre-Ship Inspection
a. Ask your in-country manager to pre-inspect each container, and/or find a third-party inspection service. You'll need to determine the sampling rates (pieces per lot code etc)
b. Ensure that vendor communicates to you any changes in staff, processes, equipment. Don't ask them to seek your approval - this will ensure they never tell you. Ask for the information and help them with any issues that arise.
c. A good vendor will have robust data recorded at every stage of the production process (for traceability and efficiency). Decide what parameters are critical for your product and design a standard Excel format that their QC personnel is to complete and send to you (or your sourcing manager) prior to container stuffing. Make sure it details each lot code.
- Confirm that they are packing exactly what is on the PO.
d. Pay attention to the container (clean, dry, no leaks/holes/rust) and container packing. Ensure: containers are packed on a dry-dock, properly squared and with adequate bracing, and if required with moisture/temperature control features
e. Take pictures of the container being stuffed: 1/3, 2/3, full, sealed (showing container # and seal). Develop a web-site where these pictures can be posted and reviewed. This helps eliminate using "it must have been during shipping" as an excuse for damaged goods.
7. Post Shipment Inspection / Issues
a. Agree with the vendor, ahead of time, how you will both deal with complaints. The purpose here is to have no surprises for anyone. An example
- For <=5 cases damaged in transit: issue L1Debit Memo and aggregate debits for once per month resolution. Also applies for short-shipments
- For <=20 cases damaged, I provide pictures and details of costs incurred. Issue L2Debit Memo, to be credited on next shipment or paid by end of month, which ever is first
- For >20 cases, file insurance claim, provide evidence of claim. Issue L3Debit Memo and collect asap. Reimburse upon settlement of insurance claim. If container has to be inspected by third-party, then agree that cost is to be borne by vendor if fault is found
b. Ensure you agree with vendor ahead of time that whether you buy FOB plant or C&F destination, if the issues are found to result from improper container stuffing, or product defects, the vendor will honor the claim.
c. Do all this even if you buy via Confirmed, Irrevocable L/C, because you are likely to need most of what is on the container and don't want to reject the entire order.
8. Documentary / Payment Control
a. If possible, structure payments to your vendor such that you pay them after you are paid by your customers
b. If it's a new relationship, bear the cost of a Confirmed, Irrevocable L/C, for at least the initial shipments
c. Never agree to pay-in-advance to secure shipments. Many Russian buyers do a lot of this, and in cash, but it's a game you should not play
d. In D/A cases, a lot of foreign companies factor receivables through the presenting bank, and then the docs will come to your bank. Of course, you can't stop them if they insist, but recognize that if they do, you won't be able to adjust claims against their invoice as it raises all kinds issues between the banks. Consider offering a small discount in order to receive documents directly (avoid all the bank notification charges) and then you can adjust small claims against their invoice.
