Case Study: LED Headlight Bulb Supply for a mining contractor in Oceania
Source:Case /
Time:2026-09-18
LED Headlight Bulb for A mining contractor in Oceania
A mining contractor came to us with a led headlight bulb programme for Oceania. 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
- Premature wear on the first batch
- A specification nobody had written down
- A fitment that looked right on paper and failed on the bench
What was specified
| Part | LED Headlight Bulb |
|---|---|
| Client | A mining contractor |
| Market | Oceania |
| Volume | 10,000 pieces across 3 specifications |
| Base material | Bronze |
| Sampling rounds | 3 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | REACH |
How it was resolved
- The specification was rebuilt around Bronze 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
- 10,000 pieces delivered inside the 8-week window.
- Unit cost held within 2.0% of the original quotation.
- Inspection-related rejection stayed under 2.0%.
- 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?
Send the part number, the annual volume and the target market, and we will come back with a specification and a sampling plan.
