Start a Small-Batch Pilot.
Typical result: OTD 98–99%+; defect <0.5%.
Indicative; actual outcomes vary by program.
Indicative; actual outcomes vary by program.
Running Small-Batch, High-Frequency Programs Without Chaos
Summary: Operate with a golden sample, a documented control plan, tighter AQL, slot-based scheduling, and weekly drops to protect cadence and quality.
The operating model (at a glance)
- Golden sample + Control plan — lock “what good looks like.”
- Tighter AQL gates — quality upfront, not at the dock.
- Slot-based scheduling — protect capacity and cadence.
- Kanban-style execution — make exceptions visible, fast.
- Traceability — batch records you can trust.
- Lock the golden sample
Approve print/finish/colors/tolerances/packaging. Write a control plan: who/when/what/how (tools).
- Set quality gates
Incoming → Inline → Final inspections.
Agree AQL (e.g., General II; Major 1.0 / Minor 2.5 or tighter).
Define rework/accept/scrap routes for fast decisions.
- Schedule by slots
Reserve weekly/bi-weekly production slots; publish a visible board. Urgent changes run through change control with a 24–48h impact assessment.
- Ship in rolling drops
Cadence > one-off pushes. Keep packaging & labels identical across drops to prevent retail issues.
- Monitor with a simple dashboard
Track: On-Time Delivery (OTD) • Defect rate (Major/Minor) • Rework ratio • Top 3 defect types • Change requests (count/age) • Upcoming slots.
Mini-FAQ
How small can we start? Typical SMB MOQs like 25/50/100 per SKU; begin with a 2-week pilot. Can you meet fixed retail packaging standards? Yes—share the spec and sampling timeline. What if we need sudden changes? We run change control (impact → approval → execution).
Get a 48-Hour Cost Scenario.
Typical result: −8–15% landed cost. Indicative; actual outcomes vary by program.
