Case Study: Fuel Tank Cap Supply for a courier company in Eastern Europe
Source:Case /
Time:2026-09-18
Fuel Tank Cap for A courier company in Eastern Europe
A courier company came to us with a fuel tank cap programme for Eastern Europe. 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
- Packing that arrived crushed at the port
- Inconsistent hardness between lots
- Premature wear on the first batch
What was specified
| Part | Fuel Tank Cap |
|---|---|
| Client | A courier company |
| Market | Eastern Europe |
| Volume | 10,000 pieces across 2 specifications |
| Base material | Titanium Alloy |
| Sampling rounds | 3 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | SAE J431 |
How it was resolved
- The specification was rebuilt around Titanium 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 6-week window.
- Unit cost held within 3.0% of the original quotation.
- Inspection-related rejection stayed under 0.5%.
- The specification is on file, so reorders reproduce the approved sample.
What we would repeat
Fix the specification count early. Adding variants after production starts is the most expensive change a client can request.
Planning something similar?
Send the specification you are working to and we will confirm what we can match, what we would change and why.
