Case Study: Brake Master Cylinder Supply for a taxi fleet in Southern Africa

Brake Master Cylinder for A taxi fleet in Southern Africa

A taxi fleet came to us with a brake master cylinder 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

• A supplier who changed material without saying so
• Lead time that slipped twice before bulk started
• A fitment that looked right on paper and failed on the bench

What was specified

How it was resolved

1. The specification was rebuilt around Polypropylene and the tolerance locked before bulk.
2. A pre-production sample was approved and kept as the golden reference.
3. Production ran with in-line inspection and a mid-run photo report.
4. Cartons were packed to the client's own barcode and ratio specification.
5. Documentation shipped with the goods instead of after them.

Result

• 2,000 pieces delivered inside the 6-week window.
• Unit cost held within 2.0% 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

Lock the material standard before sampling. Once the base changes, every downstream approval has to be redone and the calendar slips.

Planning something similar?

Send the specification you are working to and we will confirm what we can match, what we would change and why.