Loading...
Answers
MenuHow to control defects in physical products?
What systems do you use to control quality in your physical product. We have a 7% return rate on one.
Answers
If you have large quantities of batch size, look into statistical process control.
If they're smaller batches, the answer seems pretty straightforward (to me, at least):
1. Map out the production process step by step. Operations, inspections, decision points etc.
2. Install a final inspection at the end of the process to accept/reject the product.
3. Look at returns and final inspections to determine the causes of failure. You should see the 80/20 Rule in effect: about 80% of the defects will be from 20% of the sources of problems.
4. Fix those 20% of the sources and clear up most of your issues. Adjust your process flowchart to match the new method. Ensure people are following the new method.
Eventually you should have an inspection done at the end of each step / beginning of the next to ensure the product does not move on unless it is correct.
I'm an operations management guy so feel free to book a call if you wish to dig into specifics.
I have been in the electronics industry for 12+ years and 8 years in China directly handling the supply chain. I gained great expertise for each step from A to Z during product design, testing and supply chain control Even the good factories may face quality issues if you don't treat well. You can start taking actions with below questions.
1- What are the return reasons? Design related, transportation or manufacturing related? Classifying the defects from the field will help you to analyze the problem faster. Assuming here the problem is related to your manufacturer so
2- If the outgoing inspection is done by the manufacturer only, you need to add a 3rd party inspection control before shipment. If you don't have your inspection team, you can find a professional 3rd party inspection service.
3- You need to increase the inspection standard and make it tighter. I believe BS6001 standard, sampling level 2, AQL Critical: 0, Major: 0.4, Minor: 1.5 can work for you. Applying these 3 parts will help you to minimize the defected products in the field. But this is not enough. You need to solve the problem from the beginning that it won't happen again
4- For each defected unit ask an 8D report from the factory. Push them to dive into the root cause of the problems in their facility.
5- Using a professional 3rd party service apply a process audit to the factory. You need to understand where are the risky parts not only in in their manufacturing line but also in their overall operation.
6- If you are seeing any material problems, dive into the their Incoming Quality Control department. Any defected material released from IQC to the production line is a bomb waiting for exploding. You need to make sure that IQC is doing their job properly. If needed you can ask them to increase their incoming quality inspection standards. Don't forget that the more problems you fix in the early stage and fix, you will have a more reliable product and you will be more relaxed afterwards.
7- If the factory is receiving any defected materials from their own suppliers, then you may need to apply even a sub-supplier audit. All these actions can be taken easily if your factory is cooperative. If not,
8- Change your supplier and work with a more responsible factory.
These 8 items would be my main and basic control check points. If you have any questions, I more than happy to help.
It all starts with the mold. If it has the right tolerances, product will come out OK, IF the manufacturing process is stabilized and controlled as well. Do a test run to validate data, and stick to the approved parameters. Measure parts once, per shift.
We use a CMM machine that has taken our headaches away!
Related Questions
-
How do you build a MVP for an innovative tech b2b product? We would need good amount of funding to build a decent MVP and show businesses.
The idea of an MVP is 'minimum, viable' ... If you feel you need a "good amount" of funding, I would challenge if you are minimum enough. Obviously, without knowing the details of your product, your ideal customer, or what need you will solve, it is hard to help expose what is necessary in an MVP and what is a Phase II or Phase III feature. I am happy to help you work through this, or answer specific questions, to get you rolling. Just book a call with some times that will work for you. Regardless, I would love to know more about it and how it goes after launch. To your success, -ShaunSN
-
What product should I build?
You can only solve a big problem that changes the world if you solve a problem that is deeply personal to you. Two great examples and why they worked: Roy Raymond was a sad pervert. He'd buy bras and panties at the department store and all the clerks thought their thoughts about him. Roy felt embarrassed. He wasn't really a pervert. He just wanted to buy lingerie for his girlfriend. So he solved this major problem he was having. He created a space where men could feel comfortable coming in and buying sexy lingerie for their partners. He called it Victoria's Secret. But Roy, by solving this important personal issue for himself, apparently solved the same issue for many other men. First year sales were over $500,000 and he quickly opened up three more stores. In 1982 he sold Victoria's Secret for one million dollars before trying multiple other businesses that ended up failing. One MILLION Dollars. A decade later Victoria's Secret was worth over a billion dollars but Roy Raymund was nearly bankrupt and had missed the huge run-up in it's value. -- Picture New York City in the late 1800s on a rainy day. It was disgusting beyond belief. 150,000 horses transported people up and down the busy streets. Each of those horses, according to Super Freakonomics, dropped down about 15-30 pounds of manure. That's up to 4.5 million pounds of manure A DAY on the streets of NYC. And now imagine it raining. Would you cross the street? How long could this last? How long would the city survive without being infested with crap and all the diseases brought with it. What would happen as population of both men and horses increased? Was someone working on inventing a gigantic manure scooper? How would this problem get solved? It never got solved. Instead, Henry Ford invented the assembly line to mass produce cars. Every horse lost their job. People began to drive cars. Manure problem solved. -- In both cases there is a common theme. Someone outside the industry solved a problem that was personal to them that then changed an industry forever. Roy Raymund wasn't a fashion designer or a retailer. He worked in the marketing department of Vicks, which makes over the counter medications. Henry Ford, I don't think, ever worked in the manure industry. Instead, each person focused on a problem that was important to them. A problem that excited them at that moment in time. Raymund wanted to avoid being embarrassed in the future. Ford wanted an efficient way to make cars. The ONLY way to change the world is to solve a problem that is important to YOU. They had to choose themselves for success before they could save the world. Raymund had to convince himself that he didn't belong in the marketing department of a division of Procter & Gamble. He borrowed $80,000 and took the big risk of starting a business. Ford had to survive numerous failures and bankruptcies in order to find a cheap way to make cars. He would abandon investors, people who supported him, and even companies named after him, in his quest to solve his problem in his own way. Nobody gave them permission. And neither of them set out to change the world. They only wanted to solve a problem that was personally important to them. It's unfortunate that often we forget that choosing ourselves is not something that happens once. It has to happen every single day. Else we lose track of that core inside of us that solves problems and is able to share them in a way that makes the world a better place. Ford forgot this and became obsessed with Jews. Ford is the only American that Hitler mentions in Mein Kampf: "only a single great man, Ford, [who], to [the Jews'] fury, still maintains full independence...[from] the controlling masters of the producers in a nation of one hundred and twenty millions." And what happened to our embarrassed marketing manager that has ignited the passions of men and women for the past 30 years? Roy Raymund saw the value of Victoria's Secret jump from the one million he sold it for in 1982 to over a billion dollars a decade later. He failed in business after business. He got divorced. Then at the age of 46, my age, he drove to Golden Gate Bridge, jumped off it and killed himself. Before you can save the world you have to save yourself. But you have to relentlessly do it every day. Sometimes the train wakes me up at night and I feel scared. What will the world be like for my children? I won't always be able to help them. I don't even know if I do enough to help them now. And then I remember. I'm alive for another day.JA
-
What is the best method for presenting minimum viable products to potential customers?
Whoa, start by reading the Lean book again; you're questions suggest you are making a classical mistake made by too many entrepreneurs who live and breath Lean Startup. An MVP is not the least you can show someone to evaluate whether or not building it is a good idea; an MVP is, by it's very definition, the Minimum Viable Product - not less than that. What is the minimum viable version of a professional collaboration network in which users create a professional profile visible to others? A website on which users can register, have a profile, and in some way collaborate with others: via QA, chat, content, etc. No? A minimum viable product is used not to validate if something is a good idea but that you can make it work; that you can acquire users through the means you think viable, you can monetize the business, and that you can learn from the users' experience and optimize that experience by improving the MVP. Now, that doesn't mean you just go build your MVP. I get the point of your question, but we should distinguish where you're at in the business and if you're ready for an MVP or you need to have more conversations with potential users. Worth noting, MOST entrepreneurs are ready to go right to an MVP. It's a bit of a misleading convention to think that entrepreneurs don't have a clue about the industry in which they work and what customers want; that is to say, you shouldn't be an entrepreneur trying to create this professional collaboration network if you don't know the market, have done some homework, talked to peers and friends, have some experience, etc. and already know that people DO want such a thing. Presuming you've done that, what would you present to potential users BEFORE actually building the MVP? For what do you need nothing more than some slides? It's not a trick question, you should show potential users slides and validate that what you intend to build is the best it can be. I call it "coffee shop testing" - build a slide of the homepage and the main screen used by registered users; sit in a coffee shop, and buy coffee for anyone who will give you 15 minutes. Show them the two slides and listen; don't explain, ONLY ask.... - For what is this a website? - Would you sign up for it? Why? - Would you tell your friends? Why? - What would you pay for it? Don't explain ANYTHING. If you have to explain something, verbally, you aren't ready to build your MVP - potential customers don't get it. Keep working with that slide alone until you get enough people who say they will sign up and know, roughly, what people will pay. THEN build your MVP and introduce it first to friends, family, peers, etc. to get your earliest adopters. At some point you're going to explore investors. There is no "ready" as the reaction from investors will entirely depend on who you're talking to, why, how much you need, etc. If you want to talk to investors with only the slides as you need capital to build the MVP, your investors are going to be banks, grants, crowdfunding, incubators, and MAYBE angels (banks are investors?! of course they are, don't think that startups only get money from people with cash to give you for equity). Know that it's VERY hard to raise money at this stage; why would I invest in your idea when all you've done is validate that people probably want it - you haven't built anything. A bank will give you a loan to do that, not many investors will take the risk. Still, know not that your MVP is "ready" but that at THAT stage, you have certain sources of capital with which you could have a conversation. When you build the MVP, those choices change. Now that you have something, don't talk to a bank, but a grant might still be viable. Certainly: angels, crowdfunding, accelerators, and maybe even VCs become interested. The extent to which they are depends on the traction you have relative to THEIR expectations - VCs are likely to want some significant adoption or revenue whereas Angels should be excited for your early adoption and validation and interested in helping you scale.PO
-
Taking a ridesharing idea from concept to market
here is my simple advice which should save you a lot of time and money. your journey should start identifying whether or not you have a problem worth solving. Most of your issues, assumptions, solution you put forward is irrelevant until you have done this. Don't get me wrong, your idea is sound and it often starts from a vision or an intuition that your idea is great. You now need to take a step back and do a coue of things: - what problems does cabsharing solve? Share the cost? Meet new people? Etc. - how would you rate the pain i.e. have people been dying for someone to co.e up with such a concept or is it simply a nice to have You have to come up with a porblem statement, good understanding of the problem and start testing this first. Get out there and interview people. Measure. Learn. If you have not heard of it yet just follow the lean startup approach (i recommend ash maurya's blog that will give you plenty to start with - his book running lean is also a great and practical resource). If you need help structuring it all or formalising your initial lean canvas I am happy to help. The most important thing is to test and validate key assumptions before you embark on something bigger. Many ways nowadays to do this, give me a shout in less than am hour we can get you up and running. Hope that helps, good luck the exciting part is just starting now: making it happen!ES
-
I'm looking for a great full service app design firm to build my app and help with all design, branding, development, etc. Anyone know any good ones?
Yes. Who I would recommend would depend on what you'd like to see happen. Are you building only for iOS, or only for Android, or both? Will you have a bunch of content/stuff in your app or just a little? Are you thinking game or non-game app? Do you already have a big fanbase or would you be trying to build one while building the app? It's easy to save a bunch of money on mobile development if you know how, and even easier to overspend. Making an app can be a ton of fun or a major headache. I'd recommend the fun. So if you want an outside perspective, give me a ring.AC
the startups.com platform
Copyright © 2025 Startups.com. All rights reserved.