This note may appear to be off topic, but it is not. Please read.
China is changing everything!
When Taylor, then Galbraith, then Juran, Deming et all forced US manufacturers into thinking lean and mean, we made better and better stuff. Then with WWII we shifted gears into high volume production inspecting every tenth unit and accepting or rejecting but not paying much attention to process, which is Deming's real contribution to quality. The Japanese took it on and suddenly we had near zero rejects due to process control.
That is changing and we are going back to WWII practice with one major difference. There is no after assembly inspection by factory workers. The final assembly, be it a TV set, a generator or whatever is boxed and shipped to PepBoys or the like who sell it to the customers with a great big warning that once bought and out of the store it is under warranty... BUT, AND THIS IS A BIG BUT, the factory will handle it. So, we innocently buy such a device without a second thought because we US consumers have been conditioned to expect quality from our suppliers. Guess what. About one out of ten purchases will end up in the scrap heap by disgusted customers who put their belief in the good name of these vendors. Why? Because there is no factory service around where you bought the unit!
If you want to know more, follow my story. Back in the mid 90's I was general manager for a speaker manufacturer. I ran their Tijuana factory under total quality conditions never letting a defective speaker out the door. The Chinese approached our management and convinced them that the cost for the final product in a beautiful package and box would cost less, landed in LA, than the basic materials we used in making the speakers.
The factory was shut down, I was terminated and product started to roll in to the LA warehouse. About ten to twenty percent of the merchandise was defective. The owners and Chinese made a deal that the US distributor (can't call them manufacturers any more) would place a PO for 15 percent over what was needed and the factory would stand behind the rejects WHEN A CUSTOMER COMPLAINED thus taking the onerous of the transaction off the head of the 'distributor'.
That seems to be the trend in today's market place. The one exception is Harbor Freight that I know of; They do have a return policy that is valid. If your unit fails, they will exchange it on the spot. PepBoys and other read you the warranty riot act to which you agreed to and then you are in the hands of a phone bank filled with uncaring bureaucrats who speak nicely but do not solve your problem and keep you dangling until you junk the purchase, and go to another source.
How's that for a changing paradigm in quality. Will all of us in the field of making quality things be out of a job pretty soon based on high volume production and customers too compliant to really raise a fuss?
And they do it so candidly! The Pep Boy manager told us that we knew full well that once out of the store anything would have to go through the manufacturer. Only to discover there is no repair nor exchange facility anywhere near us, or if so, 'unauthorized' to make a repair. And even when we offered to pay for the repair, we could not find a repair facility for that particular unit.
Anybody else experience this shift in quality paradigm?