>It is unlikely that a Chinese manufacturer does make a bunch of frames and hopes Ridley might buy them. They produce on order is my experience. We design the part review it with the manufacturer and they make the mold and produce the number we ask. The mold is our property.
>
>Lou
My realities are somewhat different. Unfortunately, none of my past
experience involves volume bicycle manufacturing. In my father's
lingerie business, we sold almost exclusively to large department
stores. When a large number of garments was produced, we always made
extras to take care of the inevitable losses and shrinkage in the
delivery system. Shipping 1000 garments to a store's distribution
warehouse usually involved about 5 to 10% shrinkage mostly due to
theft. One might expect the stores to order 10% more than needed.
Instead, they just counted what arrived and claimed that my father's
factory didn't ship the correct number. We were forced to make up the
loss for zero profit or lose the customer.
Some department store would order from inventory at the last possible
moment to reduce warehouse requirements. We sent them an inventory
list, and they would decide what they wanted. At the time, having an
inventory was a bad thing because of California's former inventory
tax. Department stores also had the bad habit of buying exclusively
from inventory, in very large quantities and then either switch to
ordering well in advance or simply stop ordering. The purpose was to
destroy the vendors financial planning and eventually force the sale
of the business.
In the marine radio business, we were the manufacturer. There was no
way that we could accurately predict the exact number of radios
needed. Therefore, we needed to make spares to deal with any
unexpected orders. Manufacturing was setup to work most efficiently
in lots of 25 radios. At any time, we had no more than 25 of any
product in stock. Determining lot sizes was easier for commercial and
government orders, which were determined well in advance. We
typically produced at least 25 radios in advance mostly to deal with
any units that would fail post production QA inspection, so that we
could ship in exactly 25 unit lots and not need to wait until the
failed radios would be repaired or remanufactured. Inserting failed
radios back into the production line was a great way to bring
everything to a grinding halt.
In the telecom radio business we had two types of radios. Those that
were full of options and assembled to order and those that were all
the same. The former were required to be very reliable, which forced
to have the manufacturer maintain an inventory of spare modules and
even entire radios, when someone accidentally dropped the crate off
the loading dock. The latter were treated as commodity items but
which needed to be replaced quickly should there be any failures. I
don't recall the exact number of spare radios or modules, but my guess
is about 10% of the previous years shipments.
In a consumer electronics business, the product was treated like a
disposable commodity, where it was cheaper to replace a failed product
than to repair it. Therefore, there was little inventory of the
current product and no parts available. Warranty repairs of older
products were taken from current production giving the customer an
instant upgrade to the latest version. It was not unusual to have 2
or more future product revisions in the design queue. If someone
complained, they were told to wait for the next revision to hit
manufacturing.
In a different consumer electronics business, the manufacturer
outsourced their assembly to China. Because of the lack of component
tracking, the Chinese contract manufacturer built a substantial number
of "spare" PC boards. When the contract was complete and not renewed,
the manufacturer dumped all the spare, untested and failed in test
boards into the gray market. Since both the real product and the
counterfeit products were made on the same production line, there were
impossible to distinguish. In the hands of customers, the high
failure rate of these boards effectively ruined the reputation of the
manufacturer.
There are other production methods, which vary by product and company.
One size does not fit every product or company. Methods suitable for
a small craft shop is not going to work for Chinese style product
volumes. Any of the aforementioned could have been the source of the
"new" bicycle handlebars Tom found on eBay. Some might be good
quality, while others, not so good quality. As I suggested, Tom
should have them inspected before installing and riding.