Why establishing a monitoring system for Quality Assurance is so critical?
We decided to use a contractor manufacturer to mass produce our products and we’ve even selected the best Contract manufacturer for the job.
The chosen contract manufacturer has demonstrated to you their quality assurance procedures. You’ve probably seen many quality awards and diplomas on their office walls; ISO-9000 compliance, “Six Sigma” certification, “Total Quality Management” and other quality management certifications.
So now you can lean back, confident that production will run smoothly, your customers will get great quality products on time and everything is going to run like clockwork.
Well, sorry to disappoint you! You may have chosen the best Contract Manufacturer out there with a reputation for running a great production process, and a list of familiar customers as long as your arm. But consider how much time and effort went into developing your product, and how many late nights it took your team to get things just right to reach a sufficient production quality.
Can you really expect a Contract Manufacturer to be as familiar with your product as you, and pay the same level of attention that you would? Are his quality assurance procedures so reliable?
The Contract Manufacturer has probably promised you the sky (“My quality is second to none. We can react to any change in production requirements. We will always deliver on time. etc…”). All of these nice words and quality assurance count for very little, at least at the beginning of your relationship with the Contract Manufacturer.
Controlling quality in manufacturing is a field that has been researched extensively, but none of the existing quality management theories addresses the real challenges of controlling quality in manufacturing in subcontracted mass production lines. None deal with the specific need of quality assurance, controlling and production monitoring of outsourced production lines.
Despite all the advantages we’ve outlined in outsourcing your manufacturing, establishing a successful and long lasting outsourcing arrangement is inherently difficult because the parties involved have conflicting interests. And this is at the heart of the problem. You are naturally looking to for the best quality in manufacturing solution at the lowest possible price per unit, whereas the Contract Manufacturer wants to make the biggest possible profit by reducing his manufacturing costs to a minimum. In such situation the quality assurance becomes a real challenge.
With our 25 years of experience in setting up over 100 outsourced production lines, we know that you can never let your eye off the ball and get too relaxed when we are talking about quality in manufacturing.
Bear in mind that in the majority of cases your products will be shipped from your outsourced manufacturing location directly to the final customers. Any quality problems detected by the customers are going to be laid at your door. Your customer is not going to care if the problem was caused by your Contract Manufacturer. At the end of the day it’s your reputation that is at stake. That is why it is so important to choose a contract manufacture with the best quality assurance system in place.
It’s not all bad news. There are some great contract manufacturers out there running very successful production lines for their clients with a very reliable quality assurance system. The best in the business don’t work for their clients, they work in “partnership” with their clients. And if you plan to be in “partnership” mode with this key vendor, you need to understand exactly what is happening on the ground and react quickly and collaboratively.
You don’t need to be in a constant panic mode but you do need to establish a reliable, non biased and independent quality in manufacturing system to ensure real control over the production.
QualityLine will give you the tools you need to understand what is really happening to your production process. To identify potential problems even before they happen, and engage in constructive dialog with your Contract Manufacturer to ensure the timely delivery of products to your customers at the required quality level. The system helps you to continuously monitor the quality assurance level of your Contract Manufacture.
Quality in manufacturing starts here
QualityLine lets you regain control over the quality of your manufacturing line even if it is located on the other side of the world.
The system helps significantly improve quality, increase yield and minimize downtime incidents.
How does it work?
Testing data is automatically and continuously collected from your testing stations located on your manufacturing line, analyze and securely upload it to analytics dashboards exclusively set for you.
You get 24/7 accurate information about each unit tested. You can overview and drill down up to a single unit, conduct quick root cause analysis and improve production quality.