Every Day is Like Christmas Around Here

It’s always exciting to open up a new shipment of Cubelet parts.  After the UPS truck has gone and we’re left with a pile of boxes, we tend to gather around with a bit of trepidation to see what’s inside.  Some of our suppliers are boring — they always send us what we order.  But our custom parts tend to be much more exciting.  We never know what will be inside an innocuous shipping crate.

Most of our custom parts are made at factories in mainland China.  We have a metal stamping factory in the North, a magnet factory in Ningbo, a PCB factory in Wuhan, and our injection molder in the South, in Guangdong Province.  Eleven other factories make things like gears, screws, spring pins, etc.  I’ve been working directly with our suppliers now for three years, and I’ll be the first to admit that coordination and communication is a serious challenge.  It’s hard to get the right parts.

Our main challenge now seems to be getting our suppliers to send us the same parts as they did for the last order.  Almost across the board, we’ll place a re-order (“please send us 10,000 more of the exact same widget as before”) and receive something different.  It’s weird: metal parts stamped from a different material, spring pins plated differently, PCBs of the wrong thickness, and plastic parts in the wrong color.  Honestly?  It’s driving me crazy.

The latest problem popped up on Friday soon after we received 12 boxes (twelve boxes!  it’s expensive to ship 12 boxes from China to the US!) of plastic Cubelet halves.  We began assembling them into Cubelets only to find that they were all failing our connectivity test.  The little test rig shown above is made of three Cubelet pieces on a sprung platform.  As we assemble each Cubelet, we pop it in here and a series of tiny LEDs lights up to check for connectivity and short circuits.  We’ve built a different jig for every Cubelet type that runs a specific set of tests on the electronics and hardware.

After some fiddling and measuring, we found that the plastic pieces were molded wrong.  The base thickness is supposed to be 5mm with a tolerance of 0.075mm.  And these were all 5.3mm thick.  0.3mm doesn’t sound like a lot, but it’s more than enough to prevent Cubelets from communicating with neighboring Cubelets.  The upshot?  All of the plastic casings are bad.  This is unfortunate for three reasons.

Resources.  It’s unfortunate because we now have a few huge boxes of plastic and metal parts that are now useless — it’s a shameful waste.  It took a fair amount of energy and petrochemicals to make these plastic bits, and now they sit.  We’re thinking about how we might go about cracking the plastic, removing the magnets, and recycling them separately, but even this process will require more energy input.  Normally, I’m OK with making our plastic widgets because I’m confident that they’re changing kids’ minds.  But making useless plastic widgets makes me feel guilty.

Money.  This mistake is also unfortunate because it’s expensive.  It turns out to be about a $40,000 mistake, and we don’t have piles of money on hand to deal with problems like this.  We’re funded by the National Science Foundation and a few other investors, and money wasted on stuff like this is money that gets diverted away from fun projects like new Cubelets.  The most irritating part of this for me?  We pay a Quality Assurance company to check every plastic part before it’s put in the box for shipment to us.  It seems that arrangement has not worked out.

Time.  The third effect of this problem is that it puts us behind schedule.  We have 250 outstanding pre-orders for Cubelets, eager buyers emailing every day, and the holiday season creeping up.  It actually takes about five weeks to get new plastic made: first, the magnets are custom milled, then they’re sent to the injection molder to be embedded into the plastic.  Then everything gets put on a plane to Boulder, CO.

Well.  I wanted to let you what we’re up to and why we don’t have a Buy It Now button next to the Cubelets on our site.  I hope it didn’t come across as a rant.  We’re adapting and getting replacement plastic and magnets molded and shipped as quickly as possible, and we’ll carry on making as many Cubelets as we can.  Hardware is hard.

7 thoughts on “Every Day is Like Christmas Around Here

  1. Ugh. Sorry to hear this. Sad to say that this is not an uncommon experience, though. This is why any business is hard ;)

    Thanks for the update, though. Looking forward to getting my kit, though… Hope the luck improves…

  2. Thanks for the update and the insight. To address the manufacturing problems in the future, would you consider finding an American manufacturer? American quality standards are second to none. If cost is the issue, consider the $ already wasted on the latest batch of these parts, and possibly lost orders from people who decide not to wait.

  3. I have done a lot of business with Chinese manufacturing companies and the key issue with all of them is QC and repeatablity. We found that the only way to keep them ‘honest’ was to send a QC rep to the factories or appoint a local QC agent we could trust to be impartial, this way we found all errors before payment/shipment and were able to reject on the factory floor during the initial run before a complete production run was ruined.

    Looking forward to getting the cubelets some time hopefully soon.

  4. I agree with Jeff. Cheap isn’t cheap if it is late, wrong or shoddy. Perhaps something closer to home so you can save on shipping costs and spot check quality before payment.

  5. You should find some very experienced manager and send him to China, to control your suppliers due production. Without that, forget. Some people from Serbia has bad experience with sport socks, and you are talking about robots! Did you test chemical structure of plastic received from China? Don’t forget that children will try to “eat” them.
    P.S. Your product is wonderful. I hope it will be accessible in “3rd world” countries

  6. You’re making great progress and it is really inspiring to see a research project becoming a commercial product!

    Thanks a million for sharing your experiences such as the problem with the QC. This will help others avoid the same.

    All the best!

  7. I was excited when my dad told me about a company in Colorado making robots that kids could build! I have a 7 yr old that is very interested in getting a Lego Mindstorm kit. Then I found the MOSS kickstarter campaign and wanted to find out more about it. I am very excited about your product, but isn’t possible to manufacture the parts in the US? There used to be so much manufacturing here, and I’m sure you could figure out how to get the pieces made here? I would pay more for something that didn’t come from China. It seems like we barely even have a choice today to buy something that is American-made.

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