Case Study: Door Handle Supply for a wholesale group in North America
Source:Case /
Time:2026-09-18
Door Handle for A wholesale group in North America
A wholesale group came to us with a door handle 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
- Reorders that did not match the approved sample
- Inconsistent hardness between lots
- Warranty claims traced back to a single lot
What was specified
| Part | Door Handle |
|---|---|
| Client | A wholesale group |
| Market | North America |
| Volume | 10,000 pieces across 6 specifications |
| Base material | Sintered Metal |
| Sampling rounds | 3 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | ISO 9001 |
How it was resolved
- The specification was rebuilt around Sintered Metal 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 6-week window.
- Unit cost held within 1.5% of the original quotation.
- Inspection-related rejection stayed under 1.0%.
- 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?
Ask for the current catalogue and the specification sheet for this line.
