A US based retailer had established a network of factories in India manufacturing luxury home hardware. They discovered major quality issues with all their factories which were discovered much later in the value chain

Upon preliminary research, it was evident that there was a disconnect in the level of quality expected vs delivered. The factories did not have engineering specifications for material requirements, production process or dimensional limits & tolerances.

Quality Assurance: Created a quality guide that ensured suppliers are aware of quality expectations as well as what constituted a defect, performed value engineering exercise with suppliers to identify error occurrence in the production process and designed jigs & fixtures for error prevention Quality Control: Hired a team of inspectors to perform finished goods inspection before dispatch which saved plenty of time & money Engineering Design: Created detailed engineering drawings, with tolerances and specifications for every SKU (imperial to metric conversion). Drove the implementation of standardized design elements to make it easier for the factories to manufacture

The client was able to save millions of dollars in product cost, thanks to the much improved overall landed quality. In a short span of time, they were able to gain a positive reputation within their industry which drove incremental sales as well.