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Component parts are failing barely one month after China customer assembled and used it to build their final products

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1) Static very high at Customer production in rural Part of China in Guangdong.
2) Customer production process including QA/QC unproven and not ISO
3) Customer Production process very manual and labour intensive

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1) Customer operators very young and inexperienced
2) Inexperience batch of production operators

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1) Supplier poor quality batch

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1)  Customers lack equipment for manufacturing
2)  Production irregularity

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Customer manufacturing process not reliable

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Cindy

Zhi Lin

Rafee

Den

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Overstock inventory having too much unsold stock in a store.

SOLUTION

Man

Issues:

Poor forecasting

Miscommunication

Lack of training

Solutions:

Train staff

Improve coordination

Assign clear roles

Machine

Issues:

No inventory system

Outdated tools

No real-time tracking

Solutions:

Use inventory software

Add AI forecasting

Integrate sales & stock systems

Method

Issues:

Static reorder rules

No audits

Supplier-driven purchasing

Solutions:

Use dynamic reorder levels

Run regular stock reviews

Apply demand-based purchasing

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Components failed within 1 month after customer assembly.

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Components failed within 1 month after customer assembly.

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Key Facts:

-High static environment at customer factory (rural Guangdong)

-Production process not ISO certified, no proven QA/QC

-Highly manual and labour intensive

Possible Causes:

-Static discharge damage

-Manual handling errors

-No proper inspection and process control

Solutions:

Control static

-Use anti-static mats, wrist straps, grounding

Provide simple Work Instructions (WI)

-Show correct assembly & inspection steps

Do Incoming QC (IQC) for critical parts

-Check important parts before using

Pilot Run before mass production

- Small batch trial to confirm no issue

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Action Plan:

-Send anti-static and WI guidelines to customer

-Request pilot production feedback

-Monitor next batch performance

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Machine

-Defective

-Loose thread

Material

-choice of fabric

- Fitting

Method

-gifting

-generous exchange policies

-lack of transparency

-online procurement

Man

-change of mind

-Buyers remorse

-customers expectations

-Human error

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Benjamin Barker needs to find ways to upgrade its business to stay competitive and grow, as current strategies may no longer be enough to meet changing customer expectations.

Product

Limited variety or innovation in product lines (e.g. accessories, limited drops)

Lack of storytelling or differentiation between products

Price

perceived value may not match price for some customers

Place

Physical stores lack digital touch-points

People

Staff may not be trained to handle modern retail technologies

Solution

Product

upgrade the material used

have collaborations with other brands that are currently in trend

Price

have more promotions

Place

create a seamless online-offline experience

People

train the staffs