Case Study: Headlight Assembly Supply for a dealership group in Latin America
Source:Case /
Time:2026-09-18
Headlight Assembly for A dealership group in Latin America
A dealership group came to us with a headlight assembly programme for Latin 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
- Premature wear on the first batch
- Packing that arrived crushed at the port
- Lead time that slipped twice before bulk started
What was specified
| Part | Headlight Assembly |
|---|---|
| Client | A dealership group |
| Market | Latin America |
| Volume | 50,000 pieces across 3 specifications |
| Base material | Polypropylene |
| Sampling rounds | 2 |
| Delivery window | 4 weeks from PO to ex-factory |
| Compliance | ISO 9001 |
How it was resolved
- The specification was rebuilt around Polypropylene 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
- 50,000 pieces delivered inside the 4-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
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.
