In production manufacturing environment, fallout refers to parts that do not pass the necessary standards as required by the product specifications. today, we encountered a large fallout on our branded CASE123 MPS holsters from Manyi.
The hand-made sample was perfect, both in the quality and dimensions. that's why we requested a sample, to see how the workmanship and fitting would be like. but when we received our production starting order of a few hundreds of the MPS holsters, they were nowhere near acceptable; incorrect dimensions, bad workmanship, glue stains on holster surface and clips, crooked stitching, slanted holster base..... there's much more to list. from binning (manual QA to separate the good from the bad), the yield is looking like about 20% for barely passes. we'll have to find ways to salvage these holsters..... we sold one MPS-racer to a customer at regular price, he's going to have a one of a kind there.
so to recover quickly, we are in the process of contacting another manufacturing partner of ours to be our primary source. we have quickly drawn up a list of things to watch for in manufacturing, dimensions, and revised the design itself a bit. we're prepared to pay a bit extra to them just to get these out in time for Christmas shopping. Hopefully with the negotiation, we'll be able to get them to our hands in 2 weeks time.
This was somewhat expected, just not to this extent. to the journey of success, there are always roadblock that provide us with valuable lessons. This was one of them.
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