Case Study: Steering Rack Supply for a courier company in Europe

Steering Rack for A courier company in Europe

A courier company came to us with a steering rack programme for 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

• Inconsistent hardness between lots
• Documentation that arrived after the container shipped
• Packing that arrived crushed at the port

What was specified

How it was resolved

1. The specification was rebuilt around Carbon Fibre Composite 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

• 50,000 pieces delivered inside the 6-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?

Send the specification you are working to and we will confirm what we can match, what we would change and why.