Case Studies

LED lighting – Mass Production Inspection

The Devil is in the Details

When sourcing products from China, or anywhere else for that matter, it’s important to remember that, even if something seems straight forward, the opposite is often true and can result in loss of both capital and crucial lead times.

This was made evident when Amrosia was requested to approve high-end LED lighting in a mass production inspection from a new supplier a customer had selected themselves. During inspection of these goods, our inspectors found that the input voltage did not comply with the customer’s country standard and all items would need to be changed in order to be used. As a result of our due diligence, Amrosia was able to save the customer over USD $20,000 and weeks of delays.

During our inspection we relied on detailed observations of the specifications provided by the customer inMexico. Although the required power requirements were not listed on the specifications provided, our standardized procedures place this aspect of each product high on our list. Upon inspecting the samples provided by our customer’s chosen supplier, we identified the discrepancy, noting that the power standard in Mexico should be 110-120V whilst the samples were 220V.

Having failed our incoming product inspection, Amrosia immediately reported this issue with the high-end LEDs to the supplier and our customer. Our process details that all samples air freighted to our customers via our company must be verified by incoming QC and signed off on before being allowed to leave our factory or office, which ensured that this flaw was not missed.

Having highlighted the defect to the supplier and customer, Amrosia was able to send samples to the customer within a week of reporting the issue. Had our customer chosen not to utilize our services, they would have received product that simply would not work in their country, while losing over a month in time delays to have new products shipped, with resulting freight and sample costs amounting to USD $20,000 with no one on the ground to rectify the situation.

As a customer, even if you know the performance of a product and its relevant specifications, test every aspect of the product against those specifications, while also taking into account environmental factors that may be unique to the market to which those products will end up. Do not only rely on specifications and information provided but instead go the extra mile to test every aspect of the items and research the conditions and environment the items will be required to perform in.

Joint Venture, No Investment

In October 2005, one of our clients came to China so we could take them to visit several factories capable of manufacturing their labor intensive product.

AMROSIA carried out thorough factory inspections and worked with the client to negotiate with one of the factories for exclusive production of our client’s product. This kind of deal would simply not be possible without strong local understanding and cultural experience. Our expertise in this case gave our client the benefits of a joint venture without any of the investment associated with it.

USD 60,000 Saving on One Shipment

Early in 2006 AMROSIA signed an inspection contract with a large American office furniture manufacturer. The US company had been experiencing quality problems from three of their suppliers for more than two years.

AMROSIA spent time with the client to understand its quality expectations and we began doing inspections for the client in February. At one inspection, the quality of the finish on the desks was well below the client’s quality standard so we were forced to reject three 40’ containers. This saved our client from receiving more than USD 60,000 worth of defective product and incurring shipping costs on worthless product.

From 8 months to 2 weeks

In early June of 2006 we were contacted by a company that had a new, patented item (baseball training aid) that could only be marketed if manufactured in China.

The client had tried to work with a U.S. based agent to source factories in China, but had spent over 8 months trying to get samples made and approved. Once they contacted AMROSIA, we were able to supply the client with first article samples in less than 2 weeks.

Since then, we have helped the client to redesign their product to make it more durable and suited to their market. Full production has begun and the total time from initial contact to sample-making to start of production was only 6 weeks.

Does this sound like something you need? In a hurry to source high quality, competitively priced production fast? Contact us today.