Case Study: Door Handle Supply for a mining contractor in South Asia
Source:Case /
Time:2026-09-18
Door Handle for A mining contractor in South Asia
A mining contractor came to us with a door handle 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
- Premature wear on the first batch
- A specification nobody had written down
- Documentation that arrived after the container shipped
What was specified
| Part | Door Handle |
|---|---|
| Client | A mining contractor |
| Market | South Asia |
| Volume | 10,000 pieces across 4 specifications |
| Base material | EPDM Rubber |
| Sampling rounds | 4 |
| Delivery window | 4 weeks from PO to ex-factory |
| Compliance | IATF 16949 |
How it was resolved
- The specification was rebuilt around EPDM Rubber 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 4-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
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.
