Case Study: Floor Mat Supply for a spare parts retailer in North America
Source:Case /
Time:2026-09-18
Floor Mat for A spare parts retailer in North America
A spare parts retailer came to us with a floor mat programme for North America. 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
- Warranty claims traced back to a single lot
- Inconsistent hardness between lots
- A fitment that looked right on paper and failed on the bench
What was specified
| Part | Floor Mat |
|---|---|
| Client | A spare parts retailer |
| Market | North America |
| Volume | 10,000 pieces across 3 specifications |
| Base material | PVC Coated Fabric |
| Sampling rounds | 4 |
| Delivery window | 5 weeks from PO to ex-factory |
| Compliance | ISO 9001 |
How it was resolved
- The specification was rebuilt around PVC Coated Fabric 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 5-week window.
- Unit cost held within 4.5% 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
Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.
Planning something similar?
Send the specification you are working to and we will confirm what we can match, what we would change and why.
