I don’t work in the procurement end of our business, so I don’t get to see what you have described, but let me give you an alternate viewpoint: from the supplier’s end. (I know that in your position you also have that view, so this isn’t just for you; I’m sure you have your own examples.)
Several years ago when business was tight we signed a contract with an owner in a Southeast Asian country that shall not be named, who had been extremely demanding in the plant specification. We often talk about customers wanting a “gold-plated” boiler, but these people were nearly asking for that literally. And they would brook no exceptions in the proposal, either, even when we pointed out to them that their demands were not at all in line with “industry standards and practice” and would add to cost without a measurable impact on performance, reliability or longevity of the equipment, nor operations or maintenance costs. They cared not a whit for our objections to their, frankly unreasonable, demands, and since the market at the time was so ultra-competitive we caved, cut our costs prices to match / beat the competition, withdrew all of our exceptions and clarifications, basically closed our eyes and bid the project just to make a sale and continue generating revenue.
Those chickens are now coming home to roost.
We’ve started erection of the plant some months ago, and material deliveries to the site – from suppliers all over the world – are continuing apace. The utility / owner inspectors have been eagle-eyed and sharp-penciled in their criticisms – usually meaningless, according to what we all know about coal-fired boiler materials, equipment, erection and operation. For example, recently a shipment of boiler tubes was ready to leave our Chinese supplier’s facility, and were being loaded on a truck to shipment to the port for loading onto a ship for transport to the site.
The customer’s inspector rejected the shipment, sending it back to the plant for rework. The reason for the rejection? The paint on the boiler tubes had drip marks. Painted boiler tubes – with drip marks.
For those who know nothing about my industry, boiler tubes are painted to help preserve their outside surface for the months (sometimes years) while they may lay in a storage yard at the site, then moved to the staging / pre-assembly area, then erected and waiting for completion of the plant so the boiler can start operating. When the plant is completed and operating, the outside surfaces are all covered – heavily covered – with insulation and stainless steel cladding. The fire-side surfaces of the tubes have the paint burned off within hours of the plant’s starting to fire fuel. So that paint will never be seen anyway once the plant starts operation – and half of it will be gone, anyway.
The paint has absolutely zero requirement for decorative or other appearance perspective – and an inspector rejected a shipment because of paint drips. It’s simply “weather protection” for a few years while the metal is exposed to the atmosphere. This is very much analogous to rejecting delivery of a new car – which you want to buy! – because of a scuff mark on the tread of one of the tires. The scuff mark will be gone by the time you drive around the block with the new car, but “Dammit, I don’t want a scuffed tire tread! Send it back to the factory!”
In our case, this shipment, which would have been “early”, may now be “barely in time”, and depending on what the inspector sees next (because they do these things serially, too; they don’t even attempt sometimes to see all problems at once and point them out – there will be another inspection when the paint problem is corrected, and who knows what will be ‘found’ then?) … we could even be late. The project was already bid to a tighter than normal completion schedule. It remains to be seen what the compilation of these kinds of delays could do to us. This is just a more egregious example of what we’ve been seeing for years already. (Their drawing review and comment process is even worse, from what I’ve been overhearing from the engineers working with them.)
This kind of incident demonstrates a problem that even the best suppliers can face in moving to shorter and tighter supply chains and tight quality policies that attempt to take advantage of just-in-time shipping and reduced inventory: one hiccup can screw production pretty badly.