Founded in 2012, CMC includes a team of more than 20 full-time consultants and trainers. Our staff have at least 10 years’ experience driving change in Chinese organizations. They are keenly aware not only of successful management techniques that are applicable to manufacturing organizations, but also have signiﬁcant implementation experience in China.
As an organization our mission is to work as the facilitators of lasting change in Chinese companies, allowing ﬁrms to become more efﬁcient and proﬁtable.
As a manufacturer, you know that you need to keep your good customers. So your staff inspects and tests product quality. Sometimes a quality issue is caught before shipment, and you need to sort, re-work, and sometimes re-process some products.
In spite of those efforts, there are still cases where your customers complain about quality. They might charge it back to you, or switch to one of your competitors.
Inspections and testing, re-work, customer complaints… All of these cost you money. Do you know how much? Maybe it would make sense to adjust the inspection & testing budget up or down?
Can some quality issues be caught the very moment they start to appear, without the need for inspectors? In that case, your costs of quality will decrease a lot. Discover techniques and tools the best manufacturers use to improve their quality AND reduce their costs.
|Type of cost||Category name||Most common cost components|
|Losses due to quality problems out of the factory||External Failures||Penalities from Customers
Lost customers, or lower orders
Lawsuits and bad reputation
|Losses due to quality problems in the factory||Internal failures||Rework on defects
Disruption of production planning
Scrap (wasted material)
People and/or machines waiting
|Catching quality problems||Appraisal||Product QC inspection
In-line testing stations
|Avoiding quality problems||Prevention||Design for manufacturing
Statistical process control
Work instructions + training for operators and supervisors
We introduce new concepts and then immediately apply them to the trainee’s work environment. We spend some time on the shop ﬂoor, observing and discussing potential improvements. This way, the training content is immediately applied and trainees understand it in a deeper way.
20+ years manufacturing experience in various industries, including top management roles (plant manager, quality manager) at both Duracell and Honeywell in China. Experienced and trained in ISO9001, ISO 14001, ISO/TS 16949, and HACCP.
Product director for a branch of Li & Fung group, then general manager of a 1,000 people factory. Implemented ISO9001, TL9000, and ISO14001; strong experience developing FMEAs and control plans.
|09:00-09:30||Introduction||Getting to know participants, introduction of the training|
|09:30-10:30||External failures||Concept introduction, examples and cost modelling, discussion with participants (application of the concept to their work)|
|10:40-12:00||Internal failures||Concept introduction, examples and cost modelling, discussion with participants (application of the concept to their work)|
|13:30-15:00||Workshop observation||Observation of testing & inspection activities at end of line, and of a few production activities. If applicable, observation and analysis of an internal failure case.|
|15:00-15:30||Discussion about internal failures||Brainstorming about the way to address internal failures, introduction of the concepts of correction vs. corrective action|
|15:30-16:00||Appraisal||Concept introduction, cost modelling related to the factory’s situation|
|16:00-16:30||Discussion about appraisal||Brainstorming about options to make appraisal more efﬁcient|
|16:30-16:45||Summary||Wrap up of the day, reminder about main concepts and takeaways|
|09:00-09:15||Reminder||Reminder about main concepts and takeaways from previous day|
|09:15-10:30||Prevention||Overview of the most common types of prevention activities, and typical costs & beneﬁts that can be expected|
|Applicability and role of SPC (statistical process control) and preventative maintenance|
|13:30-14:00||Workshop observation||Observation of a machining of fabrication process, if applicable; outline of the ways SPC and maintenance could help|
|Applicability and role of operators training (including coaching from team leader and supervisor), and mistake prooﬁng|
|15:40-16:10||Workshop observation||Observation of an assembly process, if applicable; outline of the ways training and mistakeprooﬁng could help|
|16:10-16:45||Summary||Wrap up of the day, reminder about main concepts and takeaways|
Total costs of quality amount to 20-40% of a factory’s sales. By applying preventive measures and following the approach described by our trainers, a factory can reduce its total costs by 10-20% after about 12-18 months of work.
Some manufacturers feel the need for ongoing coaching of their team as they apply the concepts from our trainings. A good solution is to have one of our consultants come once a week for several months to reinforce the concepts and help apply them in a real situation.
Contact us for more details:
Contact us for more details:
China Manufacturing Consultants
Phone: +86 755 8253 0056 (China)
Phone: +1 443 485 6415 (US)