The Challenge
This Japanese auto parts brand had produced domestically for years, but rising labor costs and shorter lead-time requirements pushed them to consider overseas production. However, after outsourcing to Chinese factories, they couldn’t meet the quality standard (especially dimensional tolerance of ±0.02mm), and failed with three factories in a row.
Our Approach
Toei Sosan first stationed a Japanese quality management team at the Dongguan factory for two weeks, redesigning the entire manufacturing process (material receiving → machining → inspection → shipping). We created three prototype batches, measuring dimensions, surface roughness, and hardness at every stage.
Results
- Completed mass-production samples in 12 weeks
- Achieved dimensional tolerance of ±0.015mm (higher precision than the ±0.02mm required)
- 35% reduction in mass-production costs
- First-year delivery defect rate of 0.3% (equal to domestic factories)
Client Voice
“Toei’s quality management isn’t just inspection, it’s improving the entire process. We want to keep working together long-term.” — Procurement Manager
This case is published anonymously with the client’s permission.