Today, China has achieved a very special position in the area of manufacturing and production of various kinds of consumable and industrial products. Whether you are looking for textiles, automobiles, machineries, entertainment, or electronics, China can produce almost everything.
However, if you want to outsource your production in this country, then you have to move very carefully. Although Chinese made products will offer you an advantage of low cost, if the production and quality are not properly monitored, then everything can go haywire.
Poor quality products can not only upset your customers, but you may end up with severe financial damage to your business. Therefore, it is essential that you have strong control over the production and quality of your goods manufactured in China.
Random sampling can be employed to ensure the quality of your raw materials and components. If you want to verify that your manufacturer adheres to your specifications, engaging an agent to conduct a factory audit is essential. This audit will allow the agent to assess the Chinese manufacturer’s capabilities before placing an order.
It is crucial to evaluate various aspects such as production capacity, workforce skills, the manufacturing environment, machinery, and equipment. A thorough audit of this kind will provide you with a comprehensive understanding of the potential manufacturer.
In order to achieve better factory production control in China, the following strategies are being adopted by many Chinese companies these days, which will help you a lot. Let us discuss that in this post in greater detail.
1. Understanding the landscape of manufacturing in China
Before you consider the option of outsourcing your manufacturing activities in China, you must understand that China has a very high capacity for manufacturing all kinds of goods. They can rapidly scale up the production if the need arises.
So, if you have been successful in maintaining the quality of the products manufactured in China, then China will be the best place to do manufacturing at a higher scale. Key factors that impact production control encompass technological advancements, labour dynamics, regulatory environment, and the complexities of supply chains.
2. Lean manufacturing principles
Most companies of the world prefer lean manufacturing principles to minimize their waste and maximize their production. China has also adopted a similar principle, which was originally showcased by a well-known company called Toyota. The companies in China are also trying to adopt the same principle to become more efficient in their production activities.
Key elements of lean manufacturing are as follows:
a. Value stream mapping - Here, every step involved in the production activities is deeply analysed so that all the activities that do not add any value are first identified. This kind of value stream mapping in China helps the factories to recognize and eliminate those activities that have no value addition. Thus, all the bottleneck areas are eliminated in the production line, which results in lowering the cost of production and optimizing the flow of work.
b. 5S methodology - In this approach, the focus remains on the sorting, setting in order, shining, standardizing, and sustaining. The factories in China can keep their workplaces well-organized and efficient by following this 5S methodology. As a result, the production activities remain safer and more productive.
c. Kaizen - Originally, this philosophy was adopted in Japan, where more stress is given to certain smaller improvements. Companies in China have also adopted the Kaizen culture and encouraged their employees to suggest new and small improvements in their production lines.
3. Just-In-Time Production
JIT production is a crucial strategy for factory production control in China, designed to minimize inventory levels by manufacturing goods only as they are needed. This approach helps reduce holding costs and lowers the risk of overproduction. Key elements of JIT in Chinese factories include:
a. Supplier relationships - For implementing JIT in a proper manner, it is essential that companies must bond very well with their suppliers so that all the materials can reach to production floor well in time. Most Chinese companies prefer to work with their local as well as foreign suppliers very closely so that no delay ever occurs in their supplies.
b. Production scheduling - Most Chinese companies prefer to use advanced scheduling systems so that production can properly match demand forecasts. For that, much-sophisticated software has been put in place so that production schedules can be managed effectively.
c. Inventory management - JIT principle also gives enough importance to minimal inventory levels. Chinese factories utilize real-time inventory tracking systems to oversee stock levels and manage materials efficiently, thereby mitigating the risk of both excess inventory and shortages.
4. Total Quality Management
Another concept known as TQM, which is a comprehensive approach used in most production floors for quality improvement across almost every aspect of production. Key components of TQM are as follows:
a. Customer focus - Addressing the needs of the customer and also a proper understanding of it remains under main focus all throughout the Total Quality Management (TQM). In fact, these two aspects are given the top priority. Most Chinese manufacturing companies frequently try to obtain customer feedback and use that data to incorporate the necessary changes and improvements in their production process.
b. Employee involvement - It is very important to involve every employee involved in production to take initiative in quality improvement. Often various trainings are offered to workers on quality circle and problem-solving techniques.
c. Process optimization - Refinement of the complete production process is also an important part of TQM. Most factories in China apply a few important production methodologies such as Six Sigma and Statistical Process Control (SPC).
5. Advanced technology integration
Key technological strategies include:
a. Automation and robotics - These days, most Chinese companies are adopting automation and robotics to improve their precision and speed in repetitive activities. Human forces are utilized for more complex activities.
b. Internet of Things (IoT) - By adopting IoT, the entire process of production can be monitored on a real-time basis. This can be used for analysing production data, machine performance, production metrics, environmental conditions, pro-active maintenance requirement, and production optimization.
c. Big-data and analytics - By using these analytics, Chinese factories can make informed decisions based on real-time data.
6. Supply Chain Management
To effectively manage the production, it is very crucial to manage the supply chain. The following are a few key strategies adopted for that:
a. Supplier diversification - Supply diversification becomes necessary to avoid any disruption in material supply and therefore, most Chinese companies prefer to have multiple suppliers to ensure a steady flow of incoming materials for production.
b. Supply chain visibility - These days, most Chinese companies prefer to use various advanced tracking systems using software so they can do the following activities like shipment monitoring, inventory management, and anticipating and potential disruptions.
c. Risk management - There are a few risks that are beyond the preview of the company, such as geo-political tensions, and natural disaster. All that most companies do within their control is to remain alert to these developments and have a certain contingency plan to avoid such risks.
7. Regulatory compliance and environmental sustainability
These days, environmental sustainability and regulatory compliance are getting more thrust for controlling the production in China. The following strategies are adopted:
a. Adhering to regulations - All Chinese factories are supposed to comply with both local as well as international regulations on safety, quality, and environmental impact.
b. Sustainable practices - Many Chinese firms are using sustainable techniques to reduce their ecological footprint as environmental worries grow. Using eco-friendly products, adopting waste management systems, and lowering energy consumption are some strategies.
c. Certification programs - A dedication to sustainability and quality is demonstrated by obtaining certifications like ISO 14001 (Environmental Management) and ISO 9001 (Quality Management). In order to match market expectations and improve their credibility, Chinese factories strive for these certifications.
8. Employee training and development
Putting money into the training and development of employees is a key tactic for enhancing factory production control in China. Maintaining high manufacturing standards and promoting continual progress requires competent and skilled labour. Important facets of staff development consist of:
a. Skill enhancement - Production workers are encouraged to undergo new training to upgrade their skills so that they can remain up to date with current trends of the industries. Training in subjects like quality control, lean manufacturing, and technology utilization is frequently provided by Chinese producers.
b. Leadership development - Employee leadership development is essential to creating an excellence-focused culture. Chinese manufacturers make investments in leadership development initiatives to create competent managers capable of inspiring teams and boosting productivity.
c. Safety training - Creating a safe workplace is of utmost importance. Regular safety training is provided by Chinese firms to their workforce, educating them on equipment usage, emergency protocols, and best practices.
9. Customer Relationship Management
Since customer satisfaction and corporate success are directly impacted by effective customer relationship management (CRM), it is essential to factory production control. Important CRM tactics include of:
a. Customer feedback - Chinese manufacturers are better able to comprehend market demands and make the required adjustments when they collect and evaluate client input. Surveys and focus groups are two examples of feedback systems that offer insightful information for enhancing goods and services.
b. Customization and flexibility - Production process modification and flexibility are frequently needed to satisfy a wide range of customer expectations. Chinese producers use adaptable manufacturing techniques to meet different order quantities and client requirements.
c. After-sales support - Sustaining customer happiness requires providing first-rate after-sales service. Chinese factories develop comprehensive support systems to resolve issues, offer technical assistance, and guarantee a positive customer experience.
10. Strategic partnerships and collaborations
Creating strategic alliances and working together is a good way to improve industrial production control in China. Partnerships with other businesses, academic institutions, and technology suppliers can result in improvement and advantages for both parties. Important things to think about are:
a. Technology partnerships - Working together with tech companies gives Chinese manufacturers access to cutting-edge ideas and solutions.
b. Global alliances - Chinese factories can increase their competitive advantage and market reach by forming international alliances. Access to new markets, resources, and knowledge can be obtained through international partnerships.
Who can support you with quality checking services in China?
1. Manufacturers
One way can be to ask directly to your Chinese manufacturer to do a review of their production line and send you a detailed report. Although this can be the least expensive method, however, it is quite likely that manufacturers will try to cover their shortcomings. Although their quality team may be dedicated to maintaining quality, they, too, may not share facts with you. Their goal is to manufacture and deliver goods as quickly as possible, which can sometimes conflict with maintaining rigorous quality control.
2. Trading or sourcing partner
Your sourcing partner in China can be another alternative for you, who can either inspect the factory themselves or take the help of any third-party inspection company and send you a report. You can expect a little more honesty from these agencies as they would like to retain you as their client for future business. Moreover, due to their extensive trade experience, they have established numerous business relationships with various manufacturers, which can be leveraged to your advantage.
3. Self-inspection
You can opt to have your own team conduct quality checks, but this can be expensive due to the costs associated with training, accommodation, and travel, which will increase your import expenses. Alternatively, you might ask your freight forwarder to assist with random inspections as part of the shipping consolidation process.
Conclusion
Factory production control in China employs a multifaceted approach, incorporating various strategies to enhance efficiency, quality, and adaptability. By adopting all these strategies that we have explained in this article, Chinese manufacturers can maintain their global competitiveness, maintain international standards, and continuously achieve production growth.
As time progresses, many new technologies are coming in the market, and Chinese manufacturing sectors are trying to embrace them in their production system to control the production in their factory.
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