Newsletter Noviembre 2023:
By: Robert Klinger
Initial Sampling vs. Mass Production – Recognising and Minimising Risks
As the experience of some of our customers shows, it is unfortunately often the case that after the successful initial sample presentation, the quality of the series production no longer meets expectations. In the worst case, the ordered products are not usable for further production and lead to failures at the customer. The consequences are high costs and a lot of effort for employees from several departments.
Why does this happen?
During initial sampling, many suppliers do not yet have production costs in mind. This means that the initial sample parts are produced only partially under series conditions. The employees take more time for the individual process steps. This results in so-called «golden-samples». The problems come in series production when the parts must be produced under a certain cost pressure.
Recognising and minimising risks
Often our customers already have a lot of experience with comparable products. It is very helpful to know the findings from comparable products to minimise potential risks. Therefore, it is important to have an open exchange with the customer.
For example, one finds that too little attention is paid to the topic of «series packaging and transport» in the sampling phase. The initial sample lot often consists of only a few components, which are then sent to the customer with a parcel service, well packaged. When the series parts are then sent to the customer for the first time under real conditions, this can lead to transport damage. It is advisable to agree on a detailed packaging concept with the supplier in advance, taking into account the customer’s experience.
If you know the function and further processing of the component, you can also identify risks and take preventive measures. For example, you can define the scope and frequency of the series-accompanying tests for functionally relevant features. Documentation of these test features should also be agreed. This will also make the manufacturer aware of the importance of adhering to these tolerances.
In order not to jeopardise the time schedule of a new project, it is important to provide the supplier with all relevant information in detail at an early stage:
- Timetable of the project
- Scope of the initial sampling
- Packaging requirements
- Special and function-critical features
- Product and process documentation
With more than 40 years of experience in the procurement of mechanical components, we at bdp Mechanical Components can say that an open and honest relationship between customers and suppliers is the basis for the success of the project. Due to our global orientation, we can represent our customers on-site at the manufacturer’s without language or cultural differences and maintain an open and honest relationship.
Feel free to contact us at quality@bdp-mc.com with any further questions you may have regarding appropriate supplier selection.
Our bdp Mechanical Components team will be happy to advise and support you.
