Case Study: Fuel Injector Supply for a bus operator in East Africa
Source:Case /
Time:2026-09-18
Fuel Injector for A bus operator in East Africa
A bus operator came to us with a fuel injector 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 specification nobody had written down
- Inconsistent hardness between lots
What was specified
| Part | Fuel Injector |
|---|---|
| Client | A bus operator |
| Market | East Africa |
| Volume | 10,000 pieces across 4 specifications |
| Base material | Forged Aluminium |
| Sampling rounds | 3 |
| Delivery window | 5 weeks from PO to ex-factory |
| Compliance | DOT |
How it was resolved
- The specification was rebuilt around Forged Aluminium 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 5-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?
Tell us the model, the fitment and the quantity and we will hold a production slot for you.
