Case Study: Brake Disc Supply for a courier company in the Caribbean
Source:Case /
Time:2026-09-18
Brake Disc for A courier company in the Caribbean
A courier company came to us with a brake disc programme for the Caribbean. 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
- Lead time that slipped twice before bulk started
- Reorders that did not match the approved sample
- A fitment that looked right on paper and failed on the bench
What was specified
| Part | Brake Disc |
|---|---|
| Client | A courier company |
| Market | the Caribbean |
| Volume | 50,000 pieces across 4 specifications |
| Base material | Reinforced Nylon |
| Sampling rounds | 2 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | REACH |
How it was resolved
- The specification was rebuilt around Reinforced Nylon 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
- 50,000 pieces delivered inside the 8-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
Approve a pre-production sample made from the actual bulk material. Substitute material behaves differently in service.
Planning something similar?
Send the specification you are working to and we will confirm what we can match, what we would change and why.
