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Here is an example of a successful case of supplier development with a plastic extrusion company near Shanghai with whom I worked on a project of plastic extrusion parts for the automobile industry. This was a large series production for export only. The extrusion line was ready (picture 1), and the product samples passed successfully the multiple validation tests needed. But, when asked to start pre-serie production, I realized that the supplier had no process to ensure the production and meet the huge demands in daily output and quality: Once the extrusion line was started, parts were pilling up at the end of the line, falling on the ground, collected in disorder by untrained personnel, to be then checked individually… and packed later!
picture 1:
We started working hand in hand with the supplier’s technical team, exchanging ideas supported by pictures to solve this problem. I was impressed by the open-mindness of the supplier's team, its flexibility and the speed at which they could adopt new ideas: I was doing one quick follow-up visit and meeting per week, and on many occasions, an idea given was adopted and implemented the very next week, even if it implied some investment in new equipment!
In a few cycles and few weeks only, they created and tested a comfortable tailor-made process meeting all production requirements:
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jigs to control quality (picture 2) |
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production display to measure and manage production (picture 3), |
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a standardized process with only two operators properly trained to do quality check and packing (picture 4), |
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tailor made packaging to reduce shipping costs and avoid damages to parts during sea freight (picture 5). |
Nicolas C. - February 2006
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