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Opportunity:
A client was struggling to manage overseas production of a new, manually powered AM/FM radio. The product was being well received by retailers, but the client
was not able to adequately control the production rate and quality from the overseas
supplier. The result was that retailers were not getting delivery on time, and consumers
were making frequent returns.
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Challenge:
To get the client's overseas production operation under control. To initiate any engineering revisions necessary to eliminate the source of product returns and to set up proper AQL procedures to ensure consistency of product quality.
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Solution:
After IPS monitors were dispatched to the client's overseas subcontractor, it became evident that their current supplier was not capable of making the sweeping changes that would be necessary to rectify the supply and quality problems. IPS was able to set up
a second overseas supplier within a matter of weeks, and under IPS direction, the client
was able to move their entire overseas operation in an almost seamless transfer within
less than 60 days. The major sources of the quality problems were identified by IPS, and
with several minor process and material changes, production continued virtually un-interrupted.
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Result:
The client saw their production capacity dramatically increase while their quality and
returns problems were nearly eliminated. The client retained the services of IPS to continue to monitor and manage their overseas production.
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