Case Study: LED Headlight Bulb Supply for a dealership group in West Africa

LED Headlight Bulb for A dealership group in West Africa

A dealership group came to us with a led headlight bulb programme for West 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
• A fitment that looked right on paper and failed on the bench
• Lead time that slipped twice before bulk started

What was specified

How it was resolved

1. The specification was rebuilt around Magnesium Alloy 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

• 5,000 pieces delivered inside the 6-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

Approve a pre-production sample made from the actual bulk material. Substitute material behaves differently in service.

Planning something similar?

Ask for the current catalogue and the specification sheet for this line.