Case Study: EGR Valve Supply for a police fleet in North America
Source:Case /
Time:2026-09-18
EGR Valve for A police fleet in North America
A police fleet came to us with a egr valve programme for North America. 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
- Warranty claims traced back to a single lot
- Reorders that did not match the approved sample
What was specified
| Part | EGR Valve |
|---|---|
| Client | A police fleet |
| Market | North America |
| Volume | 5,000 pieces across 2 specifications |
| Base material | Carbon Fibre Composite |
| Sampling rounds | 3 |
| Delivery window | 10 weeks from PO to ex-factory |
| Compliance | REACH |
How it was resolved
- The specification was rebuilt around Carbon Fibre Composite 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
- 5,000 pieces delivered inside the 10-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
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.
