For many Western business owners, shifting manufacturing to China for cost savings is complex. Chinese quality control are prominent due to the perception that “Made in China” implies lower quality. However, many Chinese factories now exceed Western standards. Factors include global exposure, Chinese middle-class demand, and brands like Xiaomi, Haier, and Lenovo.
So, if you want to obtain good products, you should learn how to do quality control in China or other overseas countries.
East vs. West: Embracing Cultural Differences
When dealing with manufacturing in China, it’s crucial to recognize and navigate the cultural differences, especially in terms of attitudes toward quality, which often differ from those in Europe and the US. Despite China’s extensive experience as a global exporter, these differences persist, and buyers and sourcing agents frequently encounter them.
One notable aspect is the common response of “just about right.” During quality inspections, situations arise where the product exhibits unacceptable deviations, yet the factory representative insists that it’s “just about right.” However, this response falls short when a product fails to meet specified quality standards, especially when dealing with components detailed in a manufacturing agreement. Deviations of as little as 0.2 mm or variations in color within a batch may be deemed acceptable by some manufacturers but are unacceptable to many buyers and their customers. Therefore, despite occasional perceptions of excessive pickiness on the part of Chinese manufacturers, the pursuit of quality continues.
However, it’s worth noting that Western quality control standards used for auditing may not always accurately reflect the actual quality control practices within a Chinese factory, leading to my next point.
Chinese Factories: Quality Awareness over Documentation
When auditing Chinese factories using Western standards, you may encounter two common scenarios:
a. The factory’s quality control process may appear subpar on paper, but their products often meet your specifications.
b. Conversely, the factory’s quality control process might seem excellent during an audit, yet the resulting product proves to be a disappointment.
Why does this discrepancy occur?
Western quality control standards, such as having an in-process quality control officer onsite, may appear impressive on paper, and a factory may designate an individual for this role. However, it’s essential to question whether that person is genuinely qualified for the job and actively involved on the factory floor.
In practice, having an experienced individual meticulously inspect products during the manufacturing process, like an elderly worker with calipers examining each item, often proves more effective than merely having a “quality control officer” whose presence may look good on paper but doesn’t significantly contribute to maintaining quality.
In my experience, most of the factories we collaborate with excel in quality because they specialize in specific product niches. These smaller factories have in-depth knowledge of their product.
When selecting a factory in China, consider shortlisting those with a track record of manufacturing your specific product or those that have previously supplied to Western countries, as this suggests familiarity with Western quality expectations.
During negotiations with the factory, meticulously review all product specifications, requirements, and expectations, ensuring clear written communication.
It’s essential to arrange for quality control inspections or conduct them yourself. Most factories are receptive to such checks, and it’s advisable to avoid factories that resist inspections.
Following these fundamental guidelines will typically result in a satisfactory product and potentially reduce the stress associated with quality control.
Quality Tied to Manufacturing Costs
In simple terms, you get what you pay for. Raw materials, labor, electricity, and the maintenance of factory infrastructure, including machinery, all incur costs. Manufacturers have a price floor, representing the minimum expense required to maintain product quality without compromise.
On occasion, larger buyers may attempt to negotiate even lower prices with suppliers, and the supplier might agree, often due to the order’s size. However, it’s crucial to remember that an artificial reduction in price tends to have repercussions elsewhere, potentially involving the use of cheaper and lower-quality raw materials, less skilled labor, or subpar working conditions. These factors inevitably impact product quality. In the long run, such compromises can affect product delivery timelines and tarnish your reputation. Therefore, it’s essential to strike a balance between cost and quality to ensure sustainable success.
By recognizing and navigating these three key points, businesses can effectively manage and improve product quality when manufacturing in China while maintaining fruitful partnerships with Chinese suppliers.
Best Methods to Quality Control in China
A friend recently posed an interesting question: “If a buyer wants to ensure he sources quality products from China and avoids any losses, which combination of tools would you recommend (max 3)? And how would you rank them from the most effective to the least?”
Assuming the buyer knows the factory is trustworthy, let’s explore two scenarios:
For a buyer of standard (off-the-shelf) products with minimal customization:
- Final Random Inspection: This is essential, ideally conducted with a precise checklist and/or based on an approved sample provided by the buyer.
- Inspection During Production: Beneficial for the first order to address issues early.
- Factory Visit: A quick visit can help identify obviously subpar workshops. An in-depth factory audit is only warranted for larger orders from supposedly well-organized factories.
For a buyer of made-to-order products:
- Early Inspection: This is crucial, either during a pilot run or when the first finished products of bulk production are available. For complex products, consider a process review during production launch.
- Factory Capacity Audit: Assessing the factory’s capabilities is vital, especially for complex products. The buyer should have a clear profile of the ideal factory for their needs.
- Final (Pre-shipment) Inspection: This can help verify overall quality before shipment.
Bonus: If the buyer requires custom-made molds or tooling, deals with sensitive information, or has less protective payment terms, an OEM agreement is highly advisable.
These combinations of quality control methods can help buyers ensure product quality and minimize risks when sourcing from China.
Quality Control in China manufacturing for Different Industries
I’ll provide summaries for various industry verticals and highlight specific aspects of quality inspections in each:
Mechanical Products:
- Consider what is truly critical to quality (CTQ) and what doesn’t need inspection.
- Assess if there’s batch variation or if checking one piece per process is sufficient.
- Determine if recording exact values or a simple OK/Not OK result is necessary.
- Utilize go/no-go gauges for efficient inspections.
- Conduct measurement system analyses (MSA) to ensure measurement relevance.
- Don’t overlook visual checks and inspections of labeling and packing.
Garments:
- In the garment industry, some still rely on outdated methods.
- Garment inspectors should follow precise procedures.
- Carefully examine samples during the initial stages of QC.
- Pay attention to potential issues with the first piece.
- Recording measurements can be a frustrating and time-consuming task.
Electrical Home Appliances:
- Buyers often purchase a range of products within this category.
- Create category-specific checklists and adapt for model-specific differences.
- Specialized reporting software can streamline reporting.
- Larger suppliers may engage in corrective actions if needed.
- Effective follow-up on corrective actions is crucial.
Home & Decoration Products:
- Many companies rely on their catalog for product specifications.
- Time constraints often limit inspection depth.
- Products may come from various facilities, making tracking challenging.
- Quality improvement may involve switching to another supplier with fewer issues.
Furniture Items:
- Buyers often prefer using their own QC teams in furniture.
- Sampling and sample approval typically take place at the factory.
- Quality control varies between modern and antique furniture.
- Loading supervisions are important due to the impact of packing on product quality.
Promo & Gift Products:
- This category includes giveaway items, stable catalog products, and high-end brand accessories.
- Giveaway items focus on appearance, speed, and cost control.
- Stable catalog products offer consistency in quality.
- High-end brand accessories require detailed inspections with a comprehensive checklist and full reporting.