Case Study: Car Alternator Supply for a government fleet in Southern Africa
Source:Case /
Time:2026-09-18
Car Alternator for A government fleet in Southern Africa
A government fleet came to us with a car alternator programme for Southern Africa. The brief was ordinary and unforgiving at the same time: a fixed launch window, a landed cost that had to survive freight and duty, and a part that had to match an existing sample. This case records what was specified, what went wrong in sampling and how the bulk order landed.
The starting point
- Lead time that slipped twice before bulk started
- A fitment that looked right on paper and failed on the bench
- Warranty claims traced back to a single lot
What was specified
| Part | Car Alternator |
|---|---|
| Client | A government fleet |
| Market | Southern Africa |
| Volume | 5,000 pieces across 2 specifications |
| Base material | EPDM Rubber |
| Sampling rounds | 3 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | DOT |
How it was resolved
- The specification was rebuilt around EPDM Rubber and the tolerance locked before bulk.
- A pre-production sample was approved and kept as the golden reference.
- Production ran with in-line inspection and a mid-run photo report.
- Cartons were packed to the client's own barcode and ratio specification.
- Documentation shipped with the goods instead of after them.
Result
- 5,000 pieces delivered inside the 8-week window.
- Unit cost held within 1.5% of the original quotation.
- Inspection-related rejection stayed under 1.0%.
- The specification is on file, so reorders reproduce the approved sample.
What we would repeat
Fix the specification count early. Adding variants after production starts is the most expensive change a client can request.
Planning something similar?
Ask for the current catalogue and the specification sheet for this line.
