CHINA SOURCING MANAGEMENT

CHINA SOURCING MANAGEMENT CHINA SOURCING MANAGEMENT Sourcing Management Supplier Management COPYRIGHT: KPL CHINA SOURCING CO., LTD. MAIL: INFO@KPLCH...
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CHINA SOURCING MANAGEMENT CHINA SOURCING MANAGEMENT Sourcing Management

Supplier Management

COPYRIGHT: KPL CHINA SOURCING CO., LTD. MAIL: [email protected] WWW.KPLCHINASOURCING.COM

Quality Management

Project Management

Body Muscle Group Your body is divided into five major muscle groups: 1. Chest 2. Back 3. Arms & Shoulders 4. Abdominals 5. Legs (& Buttocks) Additionally, some people break the body up into three major groups: 1. Upper Body (Chest, Upper Back, Arms, Shoulders) 2. Middle Body (Abdominals, Lower Back) 3. Lower Body (Buttocks, Legs)

Fitness Equipment Standard Europe Standard BS EN 957-1:2005 一般要求 Stationary training equipment. General safety requirements and test methods BS EN 957-2:2005 力量训练器Stationary training equipment. Strength training equipment, additional specific safety requirements and test methods BS EN 957-4:2006 举重床Stationary training equipment. Strength training benches, additional specific safety requirements and test methods BS EN 957-5:2009 健身车Stationary training equipment. Stationary exercise bicycles and upper body crank training equipment, additional specific safety requirements and test methods BS EN 957-6:2001 跑步机Stationary training equipment. Treadmills, additional specific safety requirements and test methods BS EN 957-7:1999 划船器Stationary training equipment. Rowing machines, additional specific safety requirements and test methods BS EN 957-8:1998 踏步机Stationary training equipment. Steppers, stairclimbers and climbers. Additional specific safety requirements and test methods BS EN 957-9:2003 椭圆车Stationary training equipment. Elliptical trainers, additional specific safety requirements and test methods BS EN 957-10:2005 竞赛车Stationary training equipment. Exercise bicycles with a fixed wheel or without freewheel, additional specific safety requirements and test methods DIN 32935 Home sports equipment; mobile tension and pression training equipment, safety requirements, testing UL Standard UL 1647: UL Standard for Safety Motor-Operated Massage and Exercise Machines ASTM Standard ASTM_F_2216-2005 Standard Specification for Selectorized Strength Equipment ASTM_F_2276-2005 Standard Specification for Fitness Equipment1

Fitness Equipment Quality Standard System

Engineering change notices Special requirements / notice etc. Product drawings Product specification sheet, test requirements etc. Company internal standard for fitness equipment Raw material standard Surface appearance requirements Package, company logo requirements Test procedure standard Fitness equipment standard: GB,ISO, BS EN, ASTM, UL Raw material standard: carbon steel, alloy steel, aluminum, zinc alloy, plastic etc. Manufacturing process standard: forging, welding, die-casting Test standard: salt spray, hardness test, UV resistance, color inspection

BS EN 957-1 BS EN 957-1: 2005 Stationary training equipment Part 1: General safety requirements and test methods 1. Equipment classification Equipment is classified in accordance with accuracy and usage class Accuracy class: Class A: high accuracy Class B: medium accuracy Class C: minimum class Usage class: Class S (studio) : professional / commercial use Class H (home) : domestic use Class I : professional or commercial use provided for inclusive use for people with special needs this class equipment shall also be compliance with Class S requirements 2. Safety requirements 2.1 Stability of free-standing equipment carry our test with a secured person with weight 100+/-5 kg, the equipment shall not fall over at 10 ° in dynamic direction

at 5 ° in all other directions 2.2 External construction Edges: all edges and corners of surfaces which supporting bodies shall have a radius r> 2.5mm All other edges of components which are accessible to the user or third parties shall be free of burr, rounded, protested ( dimensional check and tactile examination ) Accessible tube end shall be closed off either by part of equipment or by plugs (visual inspection) Squeeze, shear, rotating and reciprocating points within the accessible area For accessible areas up to a height of 1 800 mm, when tested in accordance with 6.1.1 and 6.1.2, the distance between movable parts and adjacent movable or rigid parts shall be not less than 60 mm except as follows

BS EN 957-1 Weights The range of motion of all weights attached to the training equipment shall be limited to that required to perform the exercise 2.3 Equipment access and escape

If the user cannot attain the loaded starting position for the equipment then the equipment shall be provided with an assist means, e.g. pedal or lever to adjust the start/finish position of the exercise. 2.4 Adjustment and locking mechanisms When tested, adjustment facilities on the training equipment shall function securely, be conspicuous and safely accessible to the user. The possibility of inadvertent alteration shall be eliminated. 2.5 Ropes, belts and chains Ropes, belts, chains and attachment devices shall have a safety factor against breakage of 6 times the maximum possible tension that can be developed. The rope nominal diameter (d) shall be related to the groove radius (r) of the pulley : r=0.5d +5% to 0.5d+15% The rope ends shall be clamped flush with the clamping edge 0-2mm The possibility of a rope or a belt becoming laterally disengaged or detached shall be prevented by rope or belt guides. 2.6 Pull in points Pull in points of rope or belt drives up to 1 800 mm height shall be protected so that the user's hand, when extended, cannot be caught up. 2.7 Gripping position Integral handgrips : Gripping positions shall be clearly marked and textured to prevent slipping Applied handgrips : When tested , applied handgrips shall not be removed. 70N Rotating handgrips : Rotating handgrips shall be secured with a mechanical locking device and shall have textured surface to prevent hand slipping.

BS EN 957-1 2.8 Electrical safety 3. Test 3.1 Endurance test

a) class H 12 000 cycles over 80 % of the possible range of movement; b) class S 100 000 cycles over 80 % of the possible range of movement;

Test Finger

BS EN 957-2 Stationary training equipment — Part 2: Strength training equipment, additional specific safety requirements and test methods Safety requirements

1. Loading Intrinsic loading Each piece of equipment loaded with the user's bodymass shall withstand a force F for class H 2.5 times the bodymass (100 kg) without breakage, for class S 2 times the bodymass (100 kg) without permanent deformation. Extrinsic loading Class H F(N) = [Gk (kg) + 1,5 G (kg)] · 2,5 · 9,81m/s² Class S F (N) = [Gk (kg) + 1,5 G (kg)] · 2 · 9,81m/s² 2. Endurance load Class H 12 000 cycles over 80 % of the possible range of movement Class S 100 000 cycles over 80 % of the possible range of movement 3. Stacked weights

The uncontrolled access by third parties to squeeze and/or shear points of stacked weights shall be prevented. 4. Weight disks The maximum load ability of each weight support shall be indicated on the machine. 5. Minimum achievable training loads Machines which perform biomechanical functions should meet the minimum torque values.

BS EN 957-4 Stationary training equipment — Part 4: Strength training benches, additional specific safety requirements and test methods Safety requirements

1.

Benches with fixed barbell supports Rotational stability of the barbell Rotational stability of benches with fixed barbell supports Longitudinal stability 2. Free-standing barbell supports in conjunction with benches Free-standing barbell supports in conjunction with benches shall have a device for connecting to the ground 3. Dimensions of the barbell support

4. Barbell support strength 5. Loading 6. Barbell support Any part of the equipment intended to support free weights, shall be easily accessible to the user while accepting or replacing the barbell.

BS EN 957-5 Stationary training equipment Part 5: Stationary exercise bicycles and upper body crank training equipment, additional specific safety requirements and test methods Safety requirements

1. External construction the finger probe shall not become entrapped accessible parts of the equipment shall not have a temperature greater than 65 °C. 2. Intrinsic loading tested against permanent deformation with 2 times the maximum body mass ± 5 % specified by the manufacturer or at least 2 000 N whichever is greater. 3. Seat pillar — Seat The seat pillar shall have a permanent mark indicating the minimum insertion depth of at least 1,5 times the cross section reference dimension Except for classes HB and HC the height adjustment system shall work without a tool. The seat shall be fixed to the seat pillar and, this in turn, in the seat tube, so that the seat does not tilt more than 2° from its original position. 4. Handlebar The handlebar stem shall be adjustable or different grip positions shall be provided. If the vertical height is adjustable, the handlebar stem shall have a permanent mark indicating the minimum insertion depth of at least 1,5 times the cross section reference dimension handlebar shall function according to the manufacturer's instructions after test with a 0.3 time bodymass 5. Pedals Pedals shall be in accordance with ISO 4210. 6. Stability 7. Endurance interval test for 2 hours

BS EN 957-6 Stationary training equipment — Part 6: Treadmills, additional specific safety requirements and test methods Safety requirement

1. External construction accessible parts of the treadmill shall not have a temperature greater than 65 C. 2. Emergency stop All power driven mills shall be equipped with an emergency/safety stop switch, which should include, either a pushbutton operated switch, or a pull-cord operated switch. 3. Immobilization method 4. Stability 5. Static loading When tested, the treadmill shall withstand a force of a) 4 times the body mass (100 kg) for class H and b) 6 times for class S 6. Endurance When tested, the treadmill shall withstand a) 12 000 impacts for class H and b) 100 000 impacts for class S 7. Side handrails/front handlebar Treadmills shall be equipped with side handrails or front handlebar for user support and emergency dismount. 8. Footplatforms Treadmills shall be equipped with footplatforms. The footplatforms shall have a non slip surface of at least 400 mm 70 mm and with a friction factor of more than 0,5. 9. Electrical safety

BS EN 957-7 Stationary training equipment Part 7: Rowing machines, additional specific safety requirements and test methods Safety requirements

1. External construction 2. Intrinsic loading 3. Handles 4. Foot supports and foot straps For classes S and H, provisions shall be made for fastening the foot (foot straps) in class H: 500 N; in class S: 1 000 N; 5. Endurance test When tested , the rowing machine shall withstand: 12 000 cycles for class H; and 100 000 cycles for class S. 6. Stability Place the rowing machine on a 10Ê slope in the dynamic direction and on a 5Ê slope in all other directions.

BS EN 957-8 Stationary training equipment Part 8: Steppers, stairclimbers and climbers Additional specific safety requirements and test methods Safety requirements

1. External construction 2. Intrinsic loading 3. Handrails/handlebars 4. Foot pedals and stairs 5. Endurance test When tested, the training equipment shall withstand: 12 000 cycles for class H; and 100 000 cycles for class S. 6. Free wheel In the case of air fan or flywheel assisted steppers, the transmission assembly should be of a free wheel type.

BS EN 957-9 Stationary training equipment — Part 9: Elliptical trainers, additional specific safety requirements and test methods Safety requirement

1. External construction 2. Intrinsic loading Each piece of equipment of class H loaded with the user's body mass shall withstand 2,5 times the body mass (100 kg) without breakage. The training equipment shall withstand four times the body mass (100 kg) without breakage. 3. Handlebars The handlebars shall show no permanent deformation of more than 3 % when tested. 4. Footplatforms The footplatforms shall have a non slip surface of at least 300 mm 100 mm and with a friction factor of more than 0,5. 5. Stability 6. Endurance When tested, the training equipment shall withstand 12 000 cycles for class H and 100 000 cycles for class S.

BS EN 957-10 Stationary training equipment — Part 10: Exercise bicycles with a fixed wheel or without freewheel, additional specific safety requirements and test methods Safety requirement

1.

External construction

2.

Intrinsic loading

3.

Seat pillar — Seat

4. Handlebar The handlebar stem shall be adjustable without a tool or different grip positions shall be possible for class S equipment. For class H, if a tool is required to adjust the handlebar stem it shall be provided by the manufacturer and clear instructions of how to use it shall be given in the user's instruction manual. For both classes the handlebar shall be tested with 1,5 times the maximum body mass specified by the manufacturer or 1 500 N whichever is greater. 5. Pedals The pedals shall include a system which maintains the foot in a position preventing unintended movement. 6. Pedal crank assembly the pedal crank assembly shall withstand a force of (750 ± 10) N applied dynamically for 1 000 000 cycles with a frequency of max. 25 Hz for class S and 120 000 cycles for class H. 7. Stability 8. Locking system The exercise bicycle with a fixed wheel or without freewheel for home use (class H) shall be equipped with a locking system to prevent the uncontrolled use or moving of any rotating part of the equipment by third parties especially children. 9. Emergency braking system Exercise bicycles with a fixed wheel or without freewheel shall be equipped with an emergency brake.

Production Process Production Process

Key control parameters

Quality control plan

Raw material warehouse Raw material specification Outside dimension, thickness, quality grade, chemical composition Warehouse management: FIFO, temperature, humidity control , identification

Supplier management, supplier audit, qualification process, approved supplier list Incoming material inspection procedure

Tube cutting Equipment: profile cutting machine Cutting fixture Cutting tube length Cutting angle

Work instruction Cutting fixture inspection, adjustment Operator self-inspection QC in-process quality inspection

Equipment: tube bending machine Bending tools Bending profile Bending dimension Bending quality, no crack,

Work instruction Bending tool inspection, adjustment Operator self-inspection QC in-process quality inspection Bending machine maintain and repair

Tube bending

Production Process Production Process

Key control parameters

Quality control plan

Welding CO2 protection welding Welding voltage, current Welding wire diameter, material Pre-heating before welding Welding operation workmanship Welding joint stress Welding angle Welding dimension

Work instruction Welding fixture inspection Voltage and current adjustment Operator self-inspection QC in-process quality inspection

Heating treatment after welding Heating treatment machine Heating temperature Keeping time Cooling method , in air or in stove

Work instruction Temperature and time control QC in-process quality inspection Welding joint inspection after heating treatment

Equipment: shot blasting machine Blasting stress Blasting surface cover rate Blasting time Blasting sand material, diameter

Work instruction Machine adjustment Operator self-inspection QC in-process quality inspection Machine maintain and repair Surface roughness

shot blasting

Production Process Production Process

Key control parameters

Quality control plan

Coating Coating line Coating material Coating layer thickness Coating color Dry temperature

Work instruction Coating machine adjustment Operator self-inspection QC in-process quality inspection

Assembly Assembly tools Assembly methods Workmanship Bolt , nut, screw tighten torque Function inspection

Work instruction Operator self-inspection QC in-process quality inspection Finish product 100% inspection Function inspection

Packing methods Packing material Packing workmanship Accessories, manual, tools, etc. Warehouse management

Work instruction Operator self-inspection QC in-process quality inspection Warehouse management

Packing Warehouse

Asia Sourcing Turnover 700,000 600,000 500,000 400,000 Asia Sourcing Turnover(FOB)

300,000

Group Net Sales Turnover

200,000 100,000 0 2004

2005

2006

2007

2008

2009 USD in Thousands

Year

2004

2005

2006

2007

2008

2009

Group Net Sales Turnover

523,837

607,274

617,271

501,471

411,178

425,100

Gross Profit

238,933

262,806

266,378

179,363

150,637

157,287

Gross Profit Rate

46

43

43

36

37

37

Total Purchasing Turnover

284,904

344,468

350,893

322,108

260,541

267,813

Asia Sourcing Turnover

35,613

49,210

58,482

64,422

65,135

89,271

Data Listed Here Are Sample Only

Asia Sourcing Cost Saving 160,000 140,000 120,000 100,000 Total Asia Sourcing Cost(CIF)

80,000

Estimate USA Sourcing Cost

60,000

Gross Asia Sourcing Cost Saving

40,000 20,000 0 2004

2005

2006

2007

2008

2009

USD in Thousands

Data Listed Here Are Sample Only Asia Sourcing Turnover (FOB)

35,613

49,210

58,482

64,422

65,135

89,271

Shipping Cost&Insurance

1,781

2,460

2,924

3,221

3,257

4,464

Total Asia Sourcing Cost(CIF)

37,394

51,670

61,406

67,643

68,392

93,735

Estimate USA Sourcing Cost

54,789

75,707

89,973

99,110

100,208

137,340

Gross Asia Sourcing Cost Saving

17,396

24,037

28,566

31,467

31,816

43,605

2009 Asia Sourcing Target 90,000 80,000 70,000 60,000 50,000 40,000 30,000 20,000 10,000 0 Jan.

Feb.

Mar.

April

May

June

2009 Monthly Asia Sourcing Turnover (FOB)

July

Aug.

Sep.

Oct.

Dec.

2009 Total Asia Sourcing Turnover (FOB)

Data Listed Here Are Sample Only 2009 Asia Sourcing Turnover (FOB) Target

Nov.

USD in Thousands 89,271

Jan.

Feb.

Mar.

April

May

June

July

Aug.

Sep.

Oct.

2009 Monthly Asia Sourcing Turnover (FOB)

7,500

7,600

7,700

8,000

8,200

7,300

7,200

7,100

8,000

8,200

2009 Total Asia Sourcing Turnover (FOB)

7,500

15,100 22,800 30,800 39,000 46,300 53,500 60,600 68,600 76,800

Nov.

Dec.

2009 Asia Sourcing Amount(supplier) Month Supplier

Total Percentage Jan.

Feb.

Mar.

April

May

June

July

Aug.

Sep.

Oct.

Nov.

Dec.

2009 Monthly Asia Sourcing Turnover (FOB)

7,500

7,600

7,700

8,000

8,200

7,300

7,200

7,100

8,000

8,200

76,800

Supplier A

2,625

2,660

2,695

2,800

2,870

2,555

2,520

2,485

2,800

2,870

26,880

35

Supplier B

1,875

1,900

1,925

2,000

2,050

1,825

1,800

1,775

2,000

2,050

19,200

25

Supplier C

1,500

1,520

1,540

1,600

1,640

1,460

1,440

1,420

1,600

1,640

15,360

20

Supplier D

750

760

770

800

820

730

720

710

800

820

7,680

10

Supplier E

750

760

770

800

820

730

720

710

800

820

7,680

10

Data Listed Here Are Sample Only

USD in Thousands Supplier A Supplier B Supplier C Supplier D Supplier E

2009 Asia Sourcing Amount (category) Month Category

Total Percentage Jan.

2009 Monthly Asia 7,500 Sourcing Turnover (FOB)

Feb.

Mar.

April

May

June

July

Aug.

Sep.

Oct.

Nov.

Dec.

7,501

7,502

7,503

7,504

7,505

7,506

7,507

7,508

7,509

75,045

Treadmill

1,500

1,500

1,500

1,501

1,501

1,501

1,501

1,501

1,502

1,502

15,009

20

Elliptical

1,500

1,500

1,500

1,501

1,501

1,501

1,501

1,501

1,502

1,502

15,009

20

Bike

1,500

1,500

1,500

1,501

1,501

1,501

1,501

1,501

1,502

1,502

15,009

20

Strength Equipments

2,250

2,250

2,251

2,251

2,251

2,252

2,252

2,252

2,252

2,253

22,514

30

Accessories

750

750

750

750

750

751

751

751

751

751

7,505

10

Data Listed Here Are Sample Only

Treadmill Elliptical Bike Strength Equipments Accessories

Supplier Management Supplier classification management A type supplier: strategic partnership for core business B type supplier: long term supplier C type supplier: small, temporary supplier Supplier annual audit planning Quality management system audit Social accountability(SA8000) audit Production processes review Supplier improvement project Improve supplier internal high failure rate, for instance ,15% to 5% Improve supplier high pre-shipment inspection reject rate, for instance: 5% to 1% Using Six Sigma DMAIC methods Supplier performance management, scorecard Supplier quality performance monitor Review supplier overall performance from: quality, delivery, cost, engineering, cooperation Annual supplier meeting Gold supplier reward

New Supplier Development Step 1: New supplier profile review Basic information: establishment, location, main products, contact, type of business Finance: registered capital, year turnover, exporting share Exporting business: main market, main customers, major products exported Human resources: total, administration, engineering, quality, production Production: major production equipment, production capacity Step 2: New supplier audit Quality management system (ISO9000) audit: continuous improvement, sub-contractor management, incoming quality control, in- process quality control, finish product quality control, customer complaint resolving, equipment maintain, gauge / tooling/ tester management etc. Social Accountability (SA8000) verification Production process: production equipment, operator ability, fixture Production capability study Step 3: Supplier score analysis Non-conformance improvement Re-audit supplier for the non-conformances Step 4: Approved supplier list Unqualified supplier list

New Product Development New product research and development Design drawings, 3D, specification sheet Prototype stage Supplier make prototype according to drawing Review supplier understand for technique drawing and specification Improve design Trial-run stage Technique review with supplier engineering, quality, production team Tooling structure review, production fixture design&making, inspection gauge design&making, test instruction prepare PFMEA, process control plan, CPK study for key dimension or parameter Production process review and improvement Initial sample inspection Production part approval procedure Mass production stage In-process quality control Production process review and improvement Supplier internal finish product inspection monitor Pre-shipment inspection Quality problem resolving, corrective actions, 8D report, QC tools Product quality standard training Supplier QE, QC training Company QC training

Supplier Quality Management Pre-shipment Inspection Pass Rate 120 100 80 Total Pass Rate

60

Supplier A 40

Supplier B

20 0 Jan. Feb. Mar. April May June July Aug. Sep. Oct. Nov. Dec. Quality Problem Pareto Chart 16 14 12

Fishbone Root Cause Analysis

10 8 Total

6 4 2 0 Welding Problem

Assembly Problem

Coating Problem

Data Listed Here Are Sample Only

Appearance

Package problem

Dimension

Others

Project Management Project management New product development project, from prototype to mass production Supplier improvement project

Contact

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