Sometimes a manufacturing defect isn’t just a manufacturing defect.
A Midwest manufacturer of early childhood learning products experienced a product failure in the field.
The problem was initially believed to involve a missing weld.
However, after ITI Manufacturing investigated the failure and conducted additional testing, the team identified a more significant problem: a fault in the product’s design.
Fixing the weld alone would not fully address the underlying issue.
The company needed a solution that addressed the product design while also dealing with existing inventory.
From identifying the problem to correcting the product
ITI worked with the customer and its factory partner to investigate the failure and develop a corrective plan.
The team coordinated:
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Evaluation and testing of the product.
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Identification of the design issue.
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Revision of the product design and engineering drawings.
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Testing of the redesigned solution.
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Production of the corrected components.
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Rework and repackaging of existing inventory.
There was another complication.
The customer had limited warehouse space available to support the rework effort.
ITI arranged for the inventory to be reworked at a third-party facility, where the affected parts were replaced with redesigned components and the products were returned to their original packaging.
The result: A complete solution in a few months
ITI completed the evaluation, redesign, testing, production, inventory rework, and repackaging within a few months.
The project required relatively little involvement from the customer’s already limited internal resources.
Instead of simply addressing the initially suspected manufacturing defect, ITI helped identify and resolve the underlying design problem.
Frequently Asked Questions
The first step is to investigate the failure and determine its root cause. A problem that appears to be related to manufacturing may also involve product design, material selection, or another factor. Corrective actions should be based on testing and technical evaluation rather than assumptions.
Yes, depending on its technical capabilities. Some contract manufacturing partners can coordinate design revisions, engineering drawing updates, production testing, and manufacturing changes. ITI Manufacturing helped an early childhood learning products company investigate a field failure, revise its design, and produce corrected components.
In some situations, existing inventory can be modified or repaired to meet approved product requirements. Feasibility depends on the defect, product design, safety requirements, and applicable regulations. ITI Manufacturing coordinated the replacement of affected components and repackaging of existing inventory for one customer after a successful redesign and testing process.
Manufacturing Problems Require More Than Quick Fixes
ITI Manufacturing works with customers and international factory partners to resolve manufacturing challenges, coordinate product improvements, and manage production requirements.
