Wednesday, January 30, 2008

Winter Storms Cause Chaos Before Lunar New Year

The link below is about the terrible snow and ice storms that have hit southern and eastern China the last few days right before Chinese New Year celebrations.

The stories mention that over 100,000 people have been stranded near the Guangzhou train station alone.

Chinese New Year is as big, or bigger, than Christmas in other parts of the world. Some describe the travel that occurs around it as the largest movement of humans on the planet.

http://ap.google.com/article/ALeqM5jvk7Cm_LiUKmk09LgSM7wXayDzlwD8UEQ9400

Today 500,000 members of the Chinese army are helping to clear roads and try to get things moving. The government has also suggested that the many of the 30 million migrant workers, or "min gong" stay in Guangdong province and not try to get home. This is a terrible situation for many workers who only get to see their families one time per year.

If workers that do get home have trouble getting back, or this situation causes some workers to decide they don't need or want to be migrants any more, it may help to accelerate the movement of factories north and west, closer to local populations of labor.

Monday, January 28, 2008

What it Means for OPS to Go West and North

I understand I've caused some confusion about our developing "west and north" strategy. What going west and north means for OPS is establishing a presence in new areas with an office, local project manager engineers, and local quality inspectors. Our model requires a reasonably local presence so we can be in the factories often. We need to be in them to build relationships, monitor order progress, monitor quality, resolve problems and reduce the risk of IP theft.

So, our dilemma is when to establish offices and hire new employees further from our traditional base in southern China. When will there be enough factories in these areas to justify the investment required for new infrastructure? More to follow on this in future posts.

Tuesday, January 22, 2008

Time to Go West



Chongqing is a huge city on the Yangtze river. The new Three Gorges Dam has opened the city to larger ships, greatly improving its value as a manufacturing and commerce center. It's in the center of China, which is far to the west of the current main commerce areas on the coast.

Within the OPS organization we are trying to get our hands around how quickly to move north and west. Our traditional area of strength has been in and around Guangdong province near Hong Kong. However, costs and government incentives are making the western areas much more attractive as manufacturing options.

A focus of the Chinese government's current 5-year plan is a push to improve living standards in the west. They've implemented tax and regulatory incentives for companies to locate in or move to western areas. Pushing growth in the western areas makes excellent sense to me.

The downside with us moving west is the lack of skilled labor and infrastructure issues. Both are improving. I am pushing to have us move north and west quickly.

Chengdu is a smaller city just west of Chongqing. Inc.com recently hyped Chengdu as a "new global hot spot" for buinesses. Intel has a large operation there.

I'm sure I'll be writing more on our decisions on going north and west.

Wednesday, January 16, 2008

Brenda and Tammy

If you call our office in Loretto, MN you will most likely talk with Brenda or Tammy, and lucky you if you do. They are the heart of the organization and almost nothing gets done (at least not well) without significant input from them.

Brenda is a mom with kids into dancing, scouting, and being a princess. She manages all our administrative activities and is a master organizer. She is also a wizard at the lunch time trivia challenge.

Tammy is also a mom, with two baseball stars for kids. She manages all accounting activities and keeps us a going concern. With a main office on each side of the Pacific plus satellites, you can imagine that our accounting is pretty complex. Tammy is the source of most company-wide jokes and is our best story teller.

We're extremely lucky to have both these great ladies on our team. Give them a call anytime you have a question.

Loretto, MN office - 866-479-1409

Monday, January 14, 2008

Inflation in China

The following article does a good job of demonstrating inflation issues in China and highlighting its risks for the global economy. Several of our customers have experienced significant price increases this year, so we're living this situation.

http://www.marketwatch.com/news/story/chinas-inflation-its-spillover-whole/story.aspx?guid={804FFB25-BA02-4737-B3C7-0E57DB5F4AEE}&siteid=yahoomy

Although inflation in China is a big issue, there are several things working to offset it. First, the Chinese government is working to improve infrastructure and offer tax incentives for factories to locate in rural Western and Northern areas of the country. These areas have lower costs as they have not benefited yet from the strong growth of the economy.

Second, productivity gains are really beginning to take hold in Chinese factories. There is huge potential for productivity growth in China as it has previously not been a focus at all.

For OPS America, we know we need to help our current partner factories improve their productivity and work harder to find new partners in the north and west. Both of these are challenges for us in 2008 and, likely, beyond.

Sunday, January 13, 2008

An Example of Why Companies Need Us

Here's an AP story that highlights why companies need someone working "on the ground" in China. Although we don't work on US copyright issues - those are the responsibility of our customers - we do address all the other problems mentioned in the article.


Published: Sunday, January 13, 2008
Buyers daunted by Chinese safety scares and rip-offs, but they still come
By WILLIAM FOREMAN, The Associated Press

GUANGZHOU, China – Ron Rust and Beve Kozub were poking around the toy booths at China’s biggest trade fair two years ago when something caught their eye: pouty-faced baby dolls snuggling in light blue and pink fleece blankets, their eyes tightly shut or gazing with a newborn’s woozy stare. The American dealers plunked down $22,052 for a shipment of 2,740. But the lifelike dolls turned out to be knockoffs. Rust and Kozub were slapped with a lawsuit that could have cost them their home in Harmony, Penn.

Despite getting burned, they were back in China this fall. For new products at the right price, China is “the only option at this time,” Rust said. The Americans fell prey to one of the many dangers of China’s rough and raw capitalism. It’s a cutthroat, predatory world where many factories cut corners to make an easy buck or just stay ahead of the thousands of others vying for their business. Safety scares, copyright ripoffs and outright thuggery are endemic. Yet, foreign buyers keep snapping up toys, clothes, laptops and a myriad of other products that the world’s factory floor churns out.

Getting your hot product made in China is seen as a sure moneymaker. In the first 11 months of 2007, China’s exports totaled $1.1 trillion, up 26 percent from the same period in 2006, according to China’s Commerce Ministry. Chinese exports to the U.S. totaled $212.7 billion, a 15 percent increase from 2006, the ministry said.

The buyers are not blameless: Many breeze in on buying missions and don’t stick around to ensure the goods are made right. For consumers, it can be a dangerous and even deadly game.

Chinese-made toy trains coated with lead paint ended up in playrooms worldwide. Cough syrup containing a poisonous chemical used in antifreeze killed dozens in Latin America. A tainted pet food ingredient killed dogs and cats in North America.

Chinese officials defend their factories, saying only a tiny fraction of the billions of dollars in exports each year have problems. But it takes just one bad batch of toothpaste to cause deaths.

American doll dealers Rust and Kozub have come to China on buying missions twice a year for the past four years. “Before we ordered the dolls, we asked if the design was theirs and they said, ‘Yes,’ ” said Rust. The dealers had sold most of the order when they got sued by Ashton-Drake Galleries, a major American dealer that owns the copyright to the doll’s design, including its clutchy little hands. “When you’re in China, how can you check on copyrights?” Kozub asked. “How would you know as a buyer to go check a hand?”

Their lawyers said they didn’t stand a chance in court and would likely lose their home in a legal defeat. So they paid a settlement of $14,400 and destroyed the 107 unsold dolls. “Our business was just starting to turn a profit,” said Rust, who launched Springers Wholesale with Kozub five years ago.

In October, they returned to China’s biggest trade show, the Canton Fair in the southern city of Guangzhou, to scout for new products and confront the supplier of the copied dolls. The dollmaker’s vice general manager, David Qin, sat at a booth lined with blonde, blue-eyed dolls – all different from those the Americans had bought two years ago. Qin, a pudgy man sporting a buzz cut and a blue polo shirt, wouldn’t talk to them until he finished his takeout lunch. He crossed his arms over his chest as Rust explained the lawsuit and requested a shipment of dolls as compensation.

In the middle of the conversation, a saleswoman flicked a switch on a display doll dressed like a punk rocker with a mohawk, leopard skin coat and red guitar. The toy belted out the song, “Who let the dogs out! Hoo, hoo, hoo, hoo!”Qin said the Americans were misled by a sales representative who no longer works at the company, Yangzhou Zhongyi Toys Co. Ltd. He repeatedly told Rust to find the former employee and take up the issue with him. He was unsympathetic to Rust’s argument that the company should take responsibility for the dolls it produced.

Later, a company saleswoman, who declined to be named, tried to explain the piracy issue to an Associated Press reporter. “Well, you know, there are a lot of factories that make dolls in our city and our designs usually all end up looking the same,” she said before pausing abruptly and adding, “But I’m not sure how it happens. It’s unclear.”

After the meeting, Kozub and Rust sat at a coffee shop at the trade show and shook their heads as they rehashed the meeting. “Sometimes we scratch our heads and wonder what we’re doing here,” he said. Such incidents feed perceptions in the West that the Chinese can’t be trusted. But Robert Kapp, a business consultant with a doctorate in Chinese history, noted that the term “snake oil” was invented in the United States during the era of cowboy capitalism. “Every country goes through this period,” said Kapp, who headed the U.S.-China Business Council from 1994 to 2004. “It may be that China is going through a growth phase we went through some time ago.”

Most Chinese industrial leaders have relatively little experience. Companies that are at least 10 years old are rare. Modern principles of market research, quality control and corporate governance are virtually unknown to the new capitalists. On the Chinese side, companies complain of incessant pressure from foreign buyers to lower prices, despite rising labor and material costs. Toy prices haven’t increased much in recent years, according to NPD Group Inc., a market research group. The average selling price of a toy was $7.53 in 2006, up from $7.17 in 2005 and $6.97 in 2004.

Some foreign buyers don’t even care about quality, said Christopher Devereux, the Guangzhou-based managing director of Chinasavvy HK Ltd., which matches foreign buyers with Chinese factories. Devereux, a tall silver-haired Briton, was contacted recently by an American who wanted to order 4,000 to 5,000 MP3 players. The buyer wasn’t deterred when Devereux told him Chinasavvy lacked the expertise to do quality checks on the devices. “He just said he wasn’t too worried about the quality,” said Devereux, who declined the request. “They think: ‘Everything is made in China. Let’s just place an order over the phone.'"

Foreign buyers play Chinese manufacturers off against one another, insisting that those with solid reputations match the prices of smaller factories that even the buyers know can’t produce quality products, said Harry Chin, who was managing the booth for Guangdong Huawei Toys Crafts (Group) Co. Ltd. at the Canton Fair. But Chin thinks last year’s high-profile recalls, including Mattel Inc.’s, are curbing this practice. “More and more customers are going to the big factories. They no longer go to the small factories,” said Chin, whose big booth was lined with plastic dinosaurs, toy binoculars and singing Santa Clauses in red and green fleece snow suits.

Just 20 yards away lurked Zhang Mingliang, vice president and export manager for rival Jiansheng Arts & Gifts Co. Ltd.Zhang was watching for buyers who showed an interest in the Santa Claus dolls. Sporting a Beatles hairdo with reddish brown highlights and a lavender shirt that reeked of cigarette smoke, he ambushed buyers as they came his way. His company didn’t rent a booth, because he feared someone would steal its designs, he said. He offered to produce the same Santa Claus dolls for a much lower price. “We can do it because we have the most modern work force and production lines,” he said.

Figuring out whether to trust someone like Zhang is difficult for a smaller traders. Furniture seller Frank Carroll learned that lesson after he closed his 20-year-old factory in Dublin, Ireland, and came to China six years ago. The Irishman, who now prefers Tsingtao beer over Guinness, worked with a family-run factory in the southern Chinese city of Foshan. They became so close that he was invited to the matriarch’s birthday party at the family’s luxurious compound with swimming pool and snooker table.

But one day, the quality control worker employed by Carroll discovered invoices at the factory office for American-standard foam. That meant the 2,000 upholstered Regency-style chairs that Carroll had ordered couldn’t be sold in the British market, which requires flame retardant “BS-standard foam. ”The factory owner and his brother at first denied that the contract specified BS-standard foam, Carroll said. When he showed them the contract, they stalled for time.

Later, the mother, father, three brothers and two of their wives showed up at Carroll’s hotel. “They weren’t willing to fix the problem,” he said. “They said, ‘Can’t you sell these chairs anyway? We won’t tell anyone. Nobody will know.’ ”One of the wives began sobbing and urged him to forgive her husband and take the chairs as a face-saving gesture. Carroll refused: “Had I been found out, my business would be dead. If one person found out, I’d never be able to trade in the U.K. again.”

It wasn’t the last time he saw the chairs. “At a furniture fair six months later,” Carroll said, “they were selling the chairs at a discount price.” The experience didn’t scare him away. The trick is finding good factories and micromanaging them, said Carroll, who splits his time between Guangzhou and Dublin. He doubts the product recalls will drive away buyers. Rather, the market will become more crowded. “My biggest problem next year,” he predicted, “will be finding suppliers.”

Tuesday, January 8, 2008

An OPS America Process Example


Here's a typical new project example. A potential client we've been talking to for a while provides us drawings, specifications, samples, and target pricing on a custom component for their product. We review the project to determine if it is a good fit for us.

If it is we generate an RFQ and the OPS Hong Kong office appoints an engineer as project manager. Typically over 3-5 weeks we get quotes from 2-4 factories in China. Often we have other projects at these factories from other clients. Sometimes we have to find new factories and qualify them. We select the best quote based on factory capability, price and other factors depending on the project.

We then add our fee to the quote and submit it to the client. Usually there is a period of questions and answers going back-and-forth over the Pacific. Sometimes there is negotiation and changes to the RFQ. If the quotes is a good one, but we haven't audited the factory before, we take care of that at this point.

After all questions are answered, if the quote is attractive, the client issues a PO for tooling and/or units. Payment terms when starting a new project at a Chinese factory are very often 50% deposit and balance before shipment. After receiving the deposit, if there is tooling involved, we begin to manage all aspects of tooling approval. At this point we also develop an inspection criteria document to guide inspection of criteria not included or clear in the specification.

After tooling samples are approved we manage the production process, including performing quality inspections against the specification before shipment. We schedule shipment and handle the logistics of getting the shipment to the freight forwarder.

Typically after working on a few different components with a client they ask us to help with sub-assemblies and then finished goods. We really begin to add value when we need to manage multiple processes at different factories in Asia to produce a finished item.

This is a very general overview example. I've skipped several details that I will come back to in future posts.

Sunday, January 6, 2008

What Makes Us Different

There are very large companies that offer manufacturing services in Asia. They offer online order tracking and other great tools. However, they usually work only on very large projects, are expensive to work with and are not very flexible.

There also are very small companies that try to help companies source products from Asia. These companies don't have enough infrastructure to support custom projects.

OPS America is one of a very few companies in the middle. We offer flexible and committed service in the US and Europe and also have strong infrastructure in Asia.

Our business model is:
  • Client-focused - We work only for our clients’ interests. We do not represent specific factories.
  • Face-to-face - Our engineers and quality inspectors frequently visit the factories we utilize or are considering. We have over 20 employees in Asia. This ensures we can effectively work through problems and reduces the risk of intellectual property theft.
  • Aligned with our clients’ objectives - We do not charge retainers or research fees. We simply add our fee to our quotes. We make money when our clients save money.
  • Easy to access - There are no contracts or long-term commitments. Clients utilize our services on a purchase order basis as long as we add value. Also, payments can be made in US dollars through our main office in Loretto, MN thereby avoiding the fees related to letters of credit and other international payment mechanisms.
  • Flexible - We can handle all aspects of the transaction, or our clients can manage some aspects, like freight, themselves.
  • Transparent - We encourage our clients to visit our Asian offices and the factories we utilize for them, or other factories.

More on this in future posts.

Friday, January 4, 2008

Dan and Joel

Since I don't want to hit any subject too many times in a row, I'll pause today from describing what we do and move onto introducing two members of our team.

Dan Cook is the founder and President of OPS America. He is a veteran of the US Navy, having served on nuclear submarines as an engineer. He has a wonderful family and is one of the most optimistic people I've ever met. His nickname in the Navy was "Golden Boy" because things always seemed to go his way. That good luck is now serving us well at OPSA.

Dan has hired everyone at OPSA himself, so he truly has built the company. He also has built most of the mechanisms by which we find new customers. Like most company builders, many internal details slip by him, but he's hired detail experts in Brenda and Tammy to cover that for us (more on them in the future).

Joel Buckley is a Vice President of OPSA and the longest-tenured full-time employee after Dan. He is the marketing wizard of our team. Joel is a good golfer (although I remember winning the last OPSA golf outing), a work-out demon, and played college-level soccer. He is terrible at Dance Dance Revolution. Also, I met his girlfriend at the company Christmas party last month and she is way out of his league - smart, funny, likes football and too attractive for Joel. Hopefully for him she won't read this. Seriously though, except for his annoying support of the Vikings, he's a great guy and the company would not nearly as successful and fun without his contributions and influence.

More on the team in future posts, along with information on the fact that we have offices in Viking country (no playoffs again) and Packer country (division champs and playing in January again).

Wednesday, January 2, 2008

What We Do

In the broadest sense we help small and mid-size companies (SME's) become and stay competitive by helping them reduce their cost of goods. More specifically we provide manufacturing services, engineering services, and infrastructure in Asia for SME's from the US and Europe.

We focus on helping our clients successfully procure custom components, sub-assemblies, and/or finished goods from Asian factories. The key word there is "custom". We don't source commodities, raw materials, or off-the-shelf products. The type of custom product is not very important. Most of our current business is in metals, plastics, electronics, soft goods, and combinations thereof.


We do all this through our offices and team members in China and Thailand. We have over 20 employees in China and a handful in Thailand. More to follow on our model and details on how we execute it.

Tuesday, January 1, 2008

Our Blog Begins

Today I am beginning the blog about our company, OPS America. I'll write as often as I'm able about our successes, our struggles, and much in between. I'm not sure where this new communication vehicle for our company will take me, but as with all my OPSA experiences so far, I'm looking forward to the ride.

Our company started in September of 2001. Yes, it's true we started during the same month as the attacks of 9/11. Dan Cook, the President of OPSA, started the company that month as a one-man show. He had been working with Doug Peterson, founder and Principle of OPS Hong Kong, for quite a while before our official start. I still remember the day in my office at Graham Medical that Dan first mentioned to me his idea for OPSA. I can't believe the company is over six years old now. I'll get into more history in future posts.

2008 is a very big year for OPSA. It's a milestone year in several ways. It's also a year we need to do things differently. We've had great success so far, but it's time for new ideas and processes. As part of that I need to do things differently as well. I need to find ways to add more value for our customers, help grow our capacity and infrastructure so we can continue to grow at the fast pace of the last six years, and find new potential customers and projects that are good fits for our model.

With this in mind, I symbolically did something different today to kick-off 2008. I decided to do a polar bear swim. There are several places in Wisconsin where it's traditional to kick-off the new year with a dip in icy Lake Michigan. I went to Kewaunee, just west of Green Bay where I live, and joined the Kewaunee Polar Bear Club. The temperature was 19 degrees according to the bank in town and the water temperature was 33 degrees according to the club. It was really, really cold and I couldn't feel my fingers or toes for a good half-hour after getting out. My daughter Elise went along and took some pictures. She is planning to join me next year.


So, with this post and a jump into a freezing lake I kick-off 2008. I expect it will be an exciting year.