What’s The Problem?
The costs of these recalls are enormous. These costs include, redesign of the product, removal of all products from stores and inventory locations, destruction of the collected products, and compensation of injured parties to say nothing of the costs to the supply base and the company’s reputation.
So, why does it happen? Does the company intentionally design and make products that they know will fail some percentage of the time? Of course not! These companies intend for their products to be perfect and most of them are. The reason that some of them are not is really quite simple. Something has changed. Maybe the material changed, or a cleaning process wasn’t followed properly, or there was a temperature fluctuation, or the customer is using the product incorrectly, or one of a million other things caused the product to fail and result in a recall. In other words, variation has crept into the process.