Safer toys: Managing risks from the early stages

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Safer toys: Managing risks from the early stages

2020 was a challenging year for most industries, driving companies to adapt and disrupt their habits and ways of doing business. Despite this, the global toy industry maintained stronger-than-expected performance, with parents and grandparents looking for new ways to keep children entertained at home.

This extraordinary context, however, brought unexpected pressures to supply chains – including shortages of qualified workers, limited access to materials, difficulties in performing quality checks, and more – adding to the existing challenge of meeting stringent regulations while ensuring the timely delivery of finished goods that meet consumer expectations. Regardless of changing circumstances, the responsibilities of toy- and children-related industries remain the same: guaranteeing the safety of products to ensure that little ones always ‘play safe’.

Despite global authorities and consumer associations putting vulnerable young consumers’ safety first, many risks and non-compliances are being uncovered. In Europe alone, toys were again the most notified product in 2019, representing 29% of RAPEX alerts.

Source: RAPEX 2019 Annual Report

Today, the importance of adopting measures at the earliest stages of production is more crucial than ever, enabling brands to anticipate risks before production even begins to avoid ‘fail’ results in pre-production tests – or even worse – in pre-shipment tests. This can not only help brands save time and money but also prevent the feared product recall and consequent negative impacts.

Many precautions can be taken to secure the supply chain and reduce risks throughout the production process, such as factory audits, in-line inspections, and in-production assessments. However, some measures that can be adopted before production even starts, allowing brands to anticipate risks at the earliest stages.

Leveraging product and manufacturing expertise

At API, our product and manufacturing expertise – acquired daily, on the ground – allows us to identify and anticipate risks before they reach the production line. Our toy experts can guide and assess your teams from the design and prototype stages, helping you manage risks and make your products safer. We work closely with toy committees, keeping up to date with changes in standards and regulations and receiving the latest news on current areas of concern and hot industry topics.

Example


Some of our preventive solutions for toys in our laboratories in Asia and Europe include:

  • Product Validation Report: An exhaustive report highlighting golden sample specifications and flagging critical points that could represent a safety or quality risk. Also assesses the functionality and performance from an end-user’s perspective and provides in-depth evaluation of the toy marking.
  • Collection Review: A product review in the showroom that includes identifying risks and non-conformity of mechanical issues and advice from our experts and recommendations on product amelioration.
  • Risk Assessment on design or prototype: A risk evaluation at the initial stages of development, which identifies any critical areas for improvement and provides expert recommendations for increased product safety.
  • Marking verification: A review of regulatory markings and instruction manuals adapted to the appropriate age grade.
  • Recommendations on performance and fit-for-play: Adapted, tailor-made protocols that simulate the child’s use of and interest in the toy.
  • Pre-production test

Our experts can help you find the right solution for your needs in anticipating toy production risks.

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Collect the right data for product compliance with our I-TCF

Data has undoubtedly been one of this year’s most repeated words when discussing how to make supply chains more resilient. Collecting, sharing and analyzing the right data can enable the entire supply chain to run more efficiently thanks to more informed decisions. In the context of quality control, data remains one of the basics.

COVID-19 has brought unprecedented challenges to supply chains and highlighted the importance of increased visibility and agility to maintain product safety and quality. Ensuring product compliance with each market’s standards and regulations remains a key obligation of brands and retailers, but guaranteeing every document’s validity and accuracy is a tedious task.

Collecting the right information about a product to prove compliance with the latest applicable standards and regulations is time-consuming at best. On top of this already arduous task, brands and retailers must remain aware of changes in standards and regulations for numerous product references in their portfolio, which can be labor-intensive and prone to errors.

The I-TCF teams at API experienced that nearly one in three documents collected are not compliant and need additional follow-up steps to complete the TCF file according to requirements and establish the product’s conformity.

Documents_TCF_W

API’s team of experts can support companies in preparing a ‘digital ID’ of each product with our I-TCF solutions (Product Integrity and Technical Compliance File). This digital ID helps verify product compliance and includes key information such as applicable protocols, document validation or rejection, and validity over time. In addition to our experts’ regulatory guidance, brands appreciate the minimal investment required, enjoy a higher degree of control with our clear digital platform, and are ultimately ready to provide the valid required documentation in cases of custom verification. 

With more than 15 years’ experience developing I-TCF solutions, we can help brands and retailers save time and money on this task. We offer support with:

  • Defining the relevant scope of compliance
  • Collecting and quickly validating a high volume of documents

Interested in finding out more about how our I-TCF solutions can help your brand?

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Complement Your Own Team

The uncertain ‘new normal’ we’re facing is forcing companies around the world to adopt strategies and contingency plans that address new practical challenges, such as the reduction of workforces and international travel restrictions. However, companies need to think about the effects these changes will have on their consumers and minimize any potential negative impacts on these important relationships. Ensuring the same levels of safety and quality while guaranteeing an efficient time-to-market is critical. The consumer products and retail industry is already changing to align with these issues through speed, cost reduction, and customer focus.

 

Most commonly cited reasons for changes due to COVID-19 in ‘Consumer Products and Retail’ industry

3 reasons_COVID19

Source: McKinsey & Company, ‘The need for speed in the post-COVID-19 era – and how to achieve it’ survey, September 2020

 

But how to achieve a customer-centered strategy with an enhanced time-to-market while considering cost-reduction needs at the same time? Some of the elements required when workforces are limited and travel is restricted are:

  • Increased flexibility
  • Faster response
  • Complementary know-how

 

An Extension of Your Own Team

To support companies in their path toward the new normal, API is cooperating with brands and retailers’ internal quality and audit teams to complement them on-demand with a 360° approach to quality that provides optional solutions.



Our complementary technical support

API’s complementary technical support allows companies to benefit from additional support only when and where it’s needed with the flexibility to adapt as required. Some of the added value of our solutions include:

  • Complementary technical solutions related to quality management: larger capabilities + deeper and upstream support (eg., remote golden sample validation with techno-visualization to assist locally during the product development stage).
  • Extended geo coverage: delivering ‘A to Z’ services with dedicated support in areas where clients are not present and that are not easy not easy to travel to. 
  • Additional expertise in specific product categories: complementary knowledge and additional areas of expertise

Interested in learning more about our specific solutions?

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Remote Support: An On-site Extension of Your Teams

In the current context of travel disruption, the ‘normal practices’ adopted by many companies until now need to be reassessed. Brands and retailers must be present in factories in many cases to oversee requirements, including the evaluation of prototypes, the review of samples at the pre-production or production stage, and the selection of items for new collections. But how can companies achieve this given the current travel restrictions and without teams on-site? Occasionally, factories can send samples to the quality teams closest to them or even to the head office. However, in most circumstances, this solution would be too costly and time-consuming. To facilitate a quick decision process and speedy time-to-market, API has harnessed the latest video technology to develop a series of remote solutions. Chair_W
Assess and approve your pre-production samples live or utilize a critical eye on-site during product selection, guided by the latest technology by our team of experts

Our solutions AT THE INITIAL PRODUCT LEVEL include:

Product sample review and validation
  • Full and precise evaluation of prototype sample, engineering sample or golden sample
  • Quality check at early stage to allow further corrections and improvement
Collection review in showroom via video call at the moment of product selection:
  • Sample review
  • Conformity / non-conformity identification on mechanical issues
  • Risks & issues anticipation
  • Recommendations for amelioration
Some of the benefits of our remote solutions are:
  • Guidance by a team of experts on-site
  • Possibility to follow live, real-time events at factory / showroom through the latest technology
  • Quality and compliant products
  • Faster time-to-market vs. international shipments for approval
  • Support though all manufacturing stages
Thanks to our in-depth manufacturing knowledge and boots-on-the-ground experience, we guide you through the most critical decision processes and support you remotely with the latest technology. API puts our teams of experts at your disposal who specialize in different product categories to support all your needs remotely. Interested in learning more about how we can support you remotely with these or other solutions?
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The rise of sustainability in the furniture industry

Attitudes toward sustainability are shifting, and it has become increasingly important for brands and retailers to participate in green initiatives and develop more sustainable products and processes.

Consumers worldwide are demanding more and more sustainable products across many segments, and industries are working quickly to adapt. It is no different in the furniture sector, where growing numbers of consumers are looking for sustainable equipment for their homes and offices.

According to the 2021 Green Home Furnishings Consumer Study by the Sustainable Furnishings Council, many consumers are concerned about environmental issues such as global warming, indoor air quality, and deforestation. Practicing eco-friendly habits has become nearly universal, and purchases of environmentally safe furnishings are on the rise.

The three most important attributes respondents said they look for when purchasing furniture were unchanged from previous years, but sustainability concerns entered in the fourth position for the first time:

  • Style (100%)
  • Quality (98%)
  • Fair price (95%)
  • Made with materials and processes that do not harm the environment (86%)

According to the report, over 96% of home furnishings purchasers would choose eco-friendly home furnishings if they liked the style and the price was within their budget.

Source: 2021 Green Home Furnishings Consumer Study by the Sustainable Furnishings Council

This change in consumer preferences confirms that we are at a stage in which integrating sustainability into a company’s strategy will help it achieve a competitive advantage in the long term. There are additional reasons to shift toward a more environmentally sustainable process, including ensuring environmental compliance, corporate responsibility and transparency, saving costs with better use of natural resources, and improving the positive impact on the planet.

One of the issues the sector faces in the journey toward a more sustainable supply chain is a lack of knowledge not only from consumers but also from the different players along the product’s lifecycle. Although there has been significant improvement in recent years, sustainability remains an overwhelming topic for many furniture industry players.

Becoming more sustainable can start with small steps in any stage of the product lifecycle, such as more sustainable materials, manufacturing practices, or transportation.

Seven of the key areas that apply to environmental sustainability are:

     1.  Environmental management systems
     2.  Energy and GHG emissions
     3.  Water use
     4.  Wastewater management
     5.  Emissions to air
     6.  Waste management
     7.  Chemical management

Where is the best place to begin? The importance of a good start is to have a solid understanding of the supply chain and its different suppliers from the outset until the finished product. It will then be possible to define realistic objectives and a clear road map at both the brand and the supply chain level.


Five steps to begin your journey

    1.  Understand your supply chain
    2. Define your objectives
    3. Supply chain assessment (environmental & chemical management)
    4. Product level sustainability
    5. Traceability assessment

API’s SUSTAINABILITY SOLUTIONS

At API, we help our customers in their sustainability journey, no matter their level of maturity in the topic. Our sustainability experts can help evaluate, verify, and improve the environmental impact of your products and processes with our strategic and tailor-made solutions. We can adapt our services to your needs using a global framework, your own framework, or by helping you from scratch with API’s bespoke framework.

Our solutions cover:

  • Environmental management solutions
  • Chemical management solutions
  • Product sustainability and traceability solutions
  • Leather sustainability solutions
  • Hardgoods training resource center

You can find out more about our solutions here.

Interested in learning how we can help your brand with a tailored sustainability assessment?

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Identify assembly line issues to improve final products

Conducting final quality checks at the end of production remains very popular; however, it loses its effectiveness and efficiency when used as the only criteria for identifying risk. Because the ultimate goal is not to find a faulty part but to avoid it occurring in the first place, waiting until the end of the manufacturing process to check for quality issues can cost you more.

Defects can vary in severity from minor appearance flaws to those critical to safety. Regardless, identifying these issues when the products are already complete will, on many occasions, require the production to be reworked, wasting time and materials. This can also lead to shipment delays and additional freight costs while impacting product reliability.

Instead of relying solely on Final Random Inspections, assessing the entire manufacturing process can significantly improve finished products. Common scenarios that impact final product outcomes include:

    1.  Incoming materials are not properly stored or inspected.
    2.  Workstations are not arranged well or correctly set up.
    3.  Operators perform processes against instructions.
    4.  Station workloads are unbalanced.
    5.  Parameters of test equipment and tools are incorrect.
    6.  The operator does not understand the product quality requirements. 
    7.  The inspection plans for outgoing goods or sample sizes are insufficient. 
    8.  Not enough quality controls during the inspection process.

Three examples of common assembly line issues

It is important to understand that the complexity of the manufacturing process will vary based on the type of product – and so will the risk. A more complicated product such as an automatic coffee machine or a steam oven, or a more complex assembly process, will most likely present a higher risk level. Other contributing elements include the maturity and knowledge of the factory, the actual capabilities of the production line, familiarity of the workers with the product requirements, and more.

Issues in the assembly line can lead to faulty products, which, in some instances, can be anticipated depending on the product’s nature. Examples include: 

Examples_AL_M

Identifying the root cause of an issue can be challenging, but it is critical to detect and prevent mistakes as soon as possible in the manufacturing process. Consider implementing this five-step practice internally:

  • Build a team to address the issue.
  • Identify the risks of the mistake.
  • Find the root cause.
  • Redesign the process based on the root cause.
  • Track the solution’s performance.

 At API, we can provide support to identify, assess, and improve manufacturing processes. Our dedicated In Production Process Assessment program takes an in-depth look at in-house procedures, from outsourced materials to final assembly. Some of the program’s benefits include:

  • Identification of good practices and opportunities for improvement
  • Improved critical processes
  • Improved customer satisfaction and reduced returns. 

Interested in learning more about how we can help your brand with a tailored assessment?

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Tips to alleviate disruption when shifting sourcing location

Reshoring, offshoring, and nearshoring: these were some of the most used terms in 2020 in numerous industries, including furniture. China continues to reign as the world’s manufacturing superpower and primary supplier of all varieties of goods, but companies have begun diversifying their supply chains in recent years and pursuing alternative manufacturing hubs. COVID-19 disruptions and the US–China trade war have acted as an accelerator in many cases, urging brands to look for manufacturing sources outside China.

China is the world’s manufacturing superpower

 Source: Statista ‘Top 10 Countries by share of global manufacturing output 2018’

The global furniture industry has been seeking sourcing alternatives to China for several years already, with some manufacturing countries outside China reinforcing their position and becoming a bigger part of manufacturing production volume for some brands. Some of the countries preferred by brands and retailers include Vietnam, Cambodia, Malaysia, India, and Indonesia in Asia, Poland in Central Europe, and Mexico in Latin America. New countries mean new opportunities, but they also come with new risks. When relocating parts of production out of China, the risks include:
  • Inadequate production planning and status: When working with new suppliers, some factories may not operate at their full capacity or might have inadequate planning, making it difficult to meet production targets. It is important to check your factory records to see how many actual people are in the production line, as well as daily output and quality control reports.
  • Rushing production: With relation to the above and to ensure correct timing, some suppliers may rush to make up for lost time, tempting them to cut corners and speed up processes. This can lead to mistakes and skipping quality control measures that put the entire production at risk.
  • Raw materials shortage: New manufacturing countries do not always benefit from the same access to raw materials as China. This may result in a shortage of some materials such as specific types of wood, stone, or components, or longer delivery times.
  • Lack of quality control to ensure safety and quality: A lack of local teams onsite or experienced factory employees may decrease the level of quality control, putting product safety and production quality at risk.

How can these risks be mitigated?

The concept of shifting production to areas outside China was already on the table before the US–China trade war and COVID-19-related pressures. However, these recent issues have broadened and escalated the topic’s relevance, with many companies now considering moving ‘out of China.’ Diversifying production areas and pursuing alternative locations can help secure additional inventory and capacity. However, launching production in a new area can be challenging without the right experience or teams in that specific area. A third-party company can support brands and retailers with adapted solutions that facilitate a smooth transition that protects production quality. The crises and disruptions experienced by supply chains in recent months may be the catalyst for revisiting a more global supply chain strategy and accelerating the adoption of new models and capabilities. However, in the meantime, short-term actions are needed to respond to these challenges.

3 tips to alleviate disruption when shifting sourcing locations

Tips from a manufacturing perspective include:
  1. Increasing workforce visibility and labor planning: Having stronger visibility over actual factories and suppliers is vital to ensure production is completed on time and with the expected quality of goods.
  2. Understanding the key suppliers: Whether the orders only represent a small portion of one factory’s production lines or are flooding the lines with goods makes a significant difference in how to best interact with that factory.
  3. Increasing supply chain transparency and carefully selecting the right suppliers: It is essential that you work only with the most suitable suppliers for your production needs.

Supporting our customers with our manufacturing expertise

At API, we are putting our manufacturing experience and product expertise at the disposal of our clients to help them adjust during this challenging time. Thanks to the agility and flexibility of our teams and our local infrastructure, we speedily implement onsite solutions that respond to each clients’ particular needs. Our dedicated technician program will act as an extension of your teams onsite to ensure your products meet your safety and quality requirements. We provide support through all stages of the supply chain, from initial development and supplier selection, through the manufacturing phases, and across production safety and quality control. For example: Interested in learning more about how we can support you in new sourcing locations?
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0% risk of unexpected chemicals with Chem Scan Check™

Did you know that around 80% of chemicals in Asia are either produced locally or come from unknown sources? There are no guarantees that some of these chemicals don’t contain traces of hazardous substances, making your products and supply chains vulnerable. In 2020, one in four imported products were found to be non-compliant with REACH and CLP*, with most cases focused on the presence of the restricted substances cadmium, lead, and nickel.

 

While uncertainty around chemical composition can be toxic for consumer confidence in general, brands and retailers have different setups, needs, and levels of awareness regarding compliance, risk, and sustainability:

  • Some have mature testing programs in place and are responsive to existing pressures in their market. These companies would still benefit from a single test that can detect hundreds of substances with fast results, attractive pricing, strong service support, and the advantage of monitoring low-performing vendors and empowering high-performing vendors.
  • Other companies focus on finished products only, meaning that when they detect a risky substance, it’s often too late to cancel the order. Testing articles when they’re finished or late in the process may lead to reproducing the entire line of articles and retesting, which can blow out budgets.
  • Some companies have no system in place and no chemical or regulatory expertise but still want to offer the end-user a secure product. Generally speaking, all companies want to be more compliant and transparent.

 

As the use of recycled materials in products increases, the possibility of these materials containing unknown substances follows suit. Overall, better fashion begins with a bigger commitment to detect and address issues from the beginning, leading to less impact on the environment and society, empowering the best-performing suppliers, and focusing time and money on where the risks are high.

 

Our new solution: Chem Scan Check™

To support our partners in optimizing their testing strategies, we developed Chem Scan Check™ (CSC), which scans for more than 285 hazardous chemical substances in one go. Instead of waiting for a pass/fail outcome for expected chemicals with a traditional testing approach, we offer our partners insight into the potentiality of 285 chemicals that may be present—including those you wouldn’t usually look for in a regular test.

What does Chem Scan Check™ offer that’s different?

While our Worms Safety network proudly offers 15 laboratories globally for traditional testing methods, our broader goal is to enable our customers to anticipate risks, identify root causes, and instill a more innovative, proactive approach.

  • One test, 285 substances: Chem Scan Check™ brings to the market one test run instead of the full substance list test. With only 5g of material, you can receive a screening result in accordance with the AFIRM restricted substance list for your textiles or plastics within 72 hours—and at a cost level that makes sense. The innovative technology is applicable to all products containing plastics and textiles; however, our current scope focuses on textiles, apparel, footwear, and home textiles, including sensitive products such as baby wear.
  • Increased visibility for better business: As Chem Scan Check™ offers greater visibility over product lines, it is an excellent opportunity to achieve company strategies that are not restricted by common test parameters.
  • End-to-end solution: A key advantage of Chem Scan Check™ is that it’s applicable across the entire life cycle—from raw materials to semi-finished products to finished products—monitoring recycled materials and certified materials.
  • Customizable and adaptable: While it’s highly beneficial across the entire supply chain, CSC is a customizable concept that can address specific focus points, such as monitoring within a vendor empowerment program or complementing sustainability strategies with a scientific method.

 

Chem Scan Check™ in action

We have already experienced cases in which sensitive products such as baby wear passed a risk-based RSL test, but our Chem Scan Check (CSC) detected a non-compliance. In another case, CSC found prohibited chemicals—including phthalates and PAH—in rubber pet toys, which were possibly used to give the toys a flexible, plastic feel. In another instance, CSC detected exotic fertilizer (diammonium phosphate) within a teddy bear. The brand then uncovered that the new supplier they were working with was using local chemicals that contained the fertilizer.

 

Why 285 chemicals?

Chem Scan Check™ can actually check for more than 285 substances. Currently, over 500 substances are calibrated with external standards. However, while Chem Scan Check uses powerful solvents and equipment, there is a limitation to organic substances. Each substance in the screening process also needs to be validated with extensive research to ensure repeatability and accuracy, so we have initially focused on supporting the textile industry in relation to the AFIRM RSL. At the moment, Chem Scan Check™ in combination with additional tests for heavy metals and formaldehyde can cover 100% of substances listed under AFIRM.


Which chemicals are covered by Chem Scan Check™?
  • Phthalates
  • PAHs
  • Azo dyes
  • Disperse dyes
  • Short/middle-chained chlorinated paraffins
  • PCP
  • VOCs
  • Alkylphenol ethoxylates (APEOs, NPEOs, OPEO)
  • Dimethylfumarate (DMFu)
  • PFOA
  • And more

To cover completed RSL lists, other tests like heavy metals and formaldehyde will be tested separately.


How can Chem Scan Check™ (CSC) integrate with your chemical strategy?
  • Superior sustainability: CSC will complement your existing recycled materials testing, facilitating broader claims with the assurance that your products contain 0% of unexpected non-compliant substances.
  • Tighter risk control: CSC allows you to test more substances that you wouldn’t usually look for, generating greater visibility and reducing risk.
  • Test new areas: CSC can cover the entire life cycle of your products and will invite you to consider new testing areas of focus, such as raw materials.
  • Customizable for vendor empowerment: CSC enables you to award greater autonomy to your best-performing suppliers by allowing for random, limited checks instead of one-size-fits-all testing.
  • Preparedness for new regulations: CSC will ensure you are ready for new regulations that require increased visibility and control over substances that may be present in your products.

 

What are the product applications?
  • Unknown source chemicals
  • Chemical cocktails
  • Recycled materials
  • Sensitive products

 

*According to an ECHA report: https://echa.europa.eu/-/1-in-4-imported-products-found-to-be-non-compliant-with-reach-and-clp

 

Click here for more information about Chem Scan Check™.

Interested in finding out how Chem Scan Check™ can improve your chemical management performance?

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New European standards for outdoor candles

In December 2021, two new European standards for outdoor candles were published to help ensure a reasonable degree of safety during their use: “EN 17616:2021 Outdoor candles – Specification for fire safety” and “EN 17617:2021 Outdoor candles – Product safety labels.”

These documents specify requirements, testing methods, and labeling requirements for the fire safety of candles intended to be burned outdoors. The European standards will be given the status of a national standard, either by the publication of an identical text or by endorsement, by latest June 2022, and conflicting national standards will be withdrawn by latest June 2022.

The major new requirements for outdoor candles include:

Container candles

  • The candle shall not tip over when tested on a slope of 10°
  • The wind resistance shall have a value > 1
  • The temperature at the surface below the container shall not exceed 350°C
  • No secondary ignition shall occur for more than 10 seconds
  • The container shall not ignite or break during testing
  • The container shall not burn for longer than 15 seconds on average and 30 seconds in any individual test during the testing
  • The container shall not be completely burned away during testing
  • The candle shall not spontaneously relight after extinguishing 

Freestanding candles

  • The candle shall not tip over when tested on a slope of 10°
  • No secondary ignition shall occur for more than 10 seconds
  • The candle shall not spontaneously relight after extinguishing

 

Garden torches

  • Shall be designed to be set up and stay in a stable manner
  • No secondary ignition shall occur for more than 10 seconds
  • No burning or smoldering material shall fall off during testing
  • Candles placed on a stick shall also meet the requirements relevant for the respective candle type, except stability

 

Floating candles

  • No secondary ignition shall occur for more than 10 seconds
  • The candle shall not spontaneously relight after extinguishing


Mandatory supplementary safety information (symbols or text)

  • For outdoor use only.
  • Never leave a burning candle unattended.
  • Keep a distance of min. x m beside and y m above to things that can catch fire.
  • Keep away from children and pets.
  • Use a heat-resistant base. (Not mandatory if the container itself has a heat-resistant base)
  • Candle gets lighter during burning, protect from strong wind by using a suitable holder.” (For container candles that didn’t comply with the wind resistance requirement as specified in EN 17616)
  • Only use at cemeteries outdoors. (For grave lights only)
  • Use in a suitable bowl filled with water. (For Floating candles only)

Layout of the product safety label:


At API, we can support our customers to comply with these or other requirements for candles to further secure the safety and quality of your products.

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5 steps for importing furniture with smoother sourcing

With unprecedented quality issues facing the importing of furniture, how can we avoid lengthy delays, product recalls, and brand reputation damage before it’s too late?

Southeast Asia remains a hub for furniture imports, despite logistics, compliance, and communication barriers posing continuous challenges. Pressures stemming from COVID-19 haven’t helped, leading to brands being unable to visit their factories, shipment delays requiring more flexible and agile manufacturing, and last-minute surprises like raw materials and component shortages.

All these can put product safety and quality at risk, but following a few key steps can ensure your furniture reaches you at its optimum quality to protect your competitive advantage and meet the standards of your market destination:

1. Determine your defect classification list

This step is often an afterthought, but classifying your defects at the outset will help clarify the meaning of your furniture inspection reports.

This is the most widely used defect classification list (DCL):

Critical defect – A defect that judgment and experience indicate is likely to:

  • Result in unsafe conditions for individuals using, maintaining, or depending upon the products; or
  • Prevent performance of the tactical function of a major end item. A critical defective is a unit of product that contains one or more critical defects.

Major defect – A defect that is likely to result in failure or reduce the usability of the product for its intended purpose.

Minor defect – A defect that is not likely to reduce the usability of the product for its intended purpose or is a departure from established standards having little bearing on the effectiveness or operation of the product.

If there is no established DCL, API offers a detailed inspection checklist to proceed with the inspection.

2. Conduct an inspection during production or place a dedicated technician onsite

This is a critical stage in ensuring that your final piece of furniture reaches its expected level of quality. It allows you to identify problems before the end of production and to adopt the required corrective measures to improve results along the production line.

3. Update your furniture specifications based on in-production feedback

Consider critical areas for improvement and the points that need to be addressed, and put a strategy in place to correct them. At this stage, you will need to re-communicate your product specifications to the factory, which may bring language challenges when sourcing in Asia. You can overcome these barriers by using a neutral third-party quality provider with expertise in your sourcing area. This ‘boots on the ground’ approach will ensure that your product specifications are communicated correctly and clearly.

4. Do a root cause analysis as a preventative measure

It is important to have a root cause analysis (RCA) strategy that determines how you will handle any defective products with your supplier. This need not be a time-consuming strategy; it should simply highlight potential problem areas and make room for process optimizations.

Don’t have an RCA strategy? Follow these steps:

  • Recognize and define the problem – Acknowledge and define your furniture’s production issue.
  • Identify the causes – Go through the process of cause identification. The trick here is not to spend too much time brainstorming or mind mapping. This needn’t be a time-consuming part of the root cause analysis.
  • Identify the solutions – Based on your cause identification, you will need to determine the best possible solutions for addressing the problem to avoid it happening again.
  • Implement the solutions – If your furniture quality was compromised during the production line, you would need to begin implementing the solutions you identified to prevent future occurrences. The solution should optimize and improve your operational processes. If it doesn’t, you may need to repeat the above steps.

5. Conduct a final check with a random inspection

A final random inspection is an inspection of a small sample of your furniture prior to shipment. This is used to determine any quality defects that may have come from the production process. Questions to consider include:

  • Does the furniture sample meet all of your product specifications?
  • How many visual defects are there?
  • What onsite tests need to be done?

Key Takeaways

A clear strategy to identify risks upstream is key in producing high-quality furniture that meets customer expectations. Some of the benefits of a well-planned sourcing strategy include:

  • Improved products
  • Faster time-to-market
  • Quality budget optimization
  • Increased customer satisfaction.

The above steps should be planned and strategized for each product category that you source. At API, we support our customers with solutions all along their supply chains. Contact us now to learn more about how our furniture expertise can give your brand the competitive edge it deserves.

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