Why “China Quality” Has a Bad Reputation
For 20 years, many Japanese companies have experienced “disappointment” with Chinese factories. The reasons: vague quality standards at contract time, inspection only at final shipment, and using substitutes to cover up defects — this is industry practice.
5 Practical Tips
1. Specify AQL (Acceptable Quality Level) Before Contract
AQL is an international standard for allowed defect counts per sample size. Specify AQL 1.0 (general industrial products) or AQL 0.65 (precision parts) in the contract.
2. Set Up 3 In-Process Quality Checks (IPQC)
- Material receiving (IQC): Material certificate + measurement
- Mid-process (IPQC): Random check of dimensions and appearance
- Pre-shipment (OQC): Final 100% or sampling inspection
3. Sampling Should Be “Risk-Based,” Not “Random”
Identify processes prone to defects and focus inspection there. Chinese factory QC managers often prefer “random inspection” — but this tends to become a formality.
4. Standardize “Defect Reports” with Photos
Verbal or WeChat text reports cause misunderstandings. Standardize a “photo + dimensional data + corrective action” format.
5. Corrective Actions Must Specify “Who, By When, What”
When defects occur, don’t blame people — identify the process. “This process’s machine setting was at this temperature, so the ±0.02mm tolerance was missed” — cause identification and countermeasure are a set.
Summary
Chinese factory quality is determined not by “factory capability” but by “QC system design.” Over 5 years, Toei Sosan has worked with 50+ Chinese factories and, by implementing the above 5 points, has kept the first-delivery defect rate below 0.5%.
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