Case Study: Clutch Master Cylinder Supply for a bus operator in Southern Africa
Source:Case /
Time:2026-09-18
Clutch Master Cylinder for A bus operator in Southern Africa
A bus operator came to us with a clutch 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
- Inconsistent hardness between lots
- Lead time that slipped twice before bulk started
- Packing that arrived crushed at the port
What was specified
| Part | Clutch Master Cylinder |
|---|---|
| Client | A bus operator |
| Market | Southern Africa |
| Volume | 2,000 pieces across 6 specifications |
| Base material | ABS Plastic |
| Sampling rounds | 2 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | CCC |
How it was resolved
- The specification was rebuilt around ABS Plastic 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
- 2,000 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
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.
