Case Study: Spark Plug Supply for a police fleet in East Africa

Spark Plug for A police fleet in East Africa

A police fleet came to us with a spark plug programme for East Africa. 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

• Warranty claims traced back to a single lot
• A fitment that looked right on paper and failed on the bench
• A supplier who changed material without saying so

What was specified

How it was resolved

1. The specification was rebuilt around Silicone 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

• 10,000 pieces delivered inside the 4-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.