Case Study: Catalytic Converter Supply for a government fleet in South Asia
Source:Case /
Time:2026-09-18
Catalytic Converter for A government fleet in South Asia
A government fleet came to us with a catalytic converter programme for South Asia. 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
- Inconsistent hardness between lots
- Documentation that arrived after the container shipped
What was specified
| Part | Catalytic Converter |
|---|---|
| Client | A government fleet |
| Market | South Asia |
| Volume | 10,000 pieces across 6 specifications |
| Base material | Aluminium Alloy |
| Sampling rounds | 2 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | IATF 16949 |
How it was resolved
- The specification was rebuilt around Aluminium Alloy 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 8-week window.
- Unit cost held within 1.5% of the original quotation.
- Inspection-related rejection stayed under 1.5%.
- 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?
Share a sample or a drawing and we will quote against a written specification, not against a photograph.
