Case Study: Dual Mass Flywheel Supply for a bus operator in North America

Dual Mass Flywheel for A bus operator in North America

A bus operator came to us with a dual mass flywheel 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

• A supplier who changed material without saying so
• Inconsistent hardness between lots
• Premature wear on the first batch

What was specified

How it was resolved

1. The specification was rebuilt around Carbon Steel 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

• 20,000 pieces delivered inside the 6-week window.
• Unit cost held within 4.5% 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

Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.

Planning something similar?

Share a sample or a drawing and we will quote against a written specification, not against a photograph.