Brief → Spec Lock (48–72 hrs)

• Translate your SKU into a Spec Pack: drawings, dims/tolerances, finishes, materials, RSL/ESG needs, packaging, labels, test methods, target landed cost, volume curve, Incoterms.
  
• Deliverables: Spec Pack v1, HS code hypothesis, landed-cost template (EXW→DDP).
  

Cluster Mapping & Longlist (Week 1)

• Map the SKU to India’s strongest manufacturing clusters (e.g., Moradabad–brass, Tiruppur–knitwear, Pune/Rajkot–auto parts, Jodhpur–furniture, Kanpur/Chennai–leather).
  
• Build a 10–15 supplier longlist with machine lists, capacity, export history, certifications, MOQs, lead times, and sample SLAs.
  

Due Diligence & Shortlist (Week 2)

• Remote and on-site factory audits: quality (ISO 9001/IATF), social (SEDEX/BSCI), environment (ISO 14001/ZDHC where relevant).
  
• Scorecard (0–100) across Quality, Compliance, Cost, Capacity, Communication. Shortlist 3–5 vendors.
  

Sampling Program (Week 2–4)

• Issue drawings/BOMs → T0/T1/T2 sample cycle to reach a Golden Sample.
  
• Lock BOM & tolerances, color/finish standards, packaging specs, and AQL plan (ANSI/ASQ Z1.4; typical General II: Major 2.5 / Minor 4.0).
  
• Deliverables: Golden Sample, signed Spec & Quality Agreement, packaging die-lines.
  

Costing & Landed-Cost Simulation

• Multi-vendor should-cost analysis (material yields, routing, cycle times).
  
• Validate HS code; model duties/FTAs (e.g., UAE CEPA, Australia ECTA), freight lanes, and surcharges → apples-to-apples China vs. India parity view.
  
• Deliverables: Vendor cost breakdowns, route options (ocean/air), EXW→FOB→CIF→DDP scenarios.
  

Pilot Order & First Article

• Place pilot PO (e.g., 50–500 units / component set) to validate tooling, cycle time, and process controls.
  
• FAI/PPAP (for engineered parts): Dimensional report, material certs, control plan, PFMEA, capability (Cp/Cpk ≥ 1.33 on critical).
  
• Deliverables: Pilot run report, defect Pareto, corrective actions.
  

Production with Stage-Gates

• IQC: incoming material checks (mill certs, lab tests as needed).
  
• IPQC: in-process checks at defined checkpoints; SPC on critical CTQs.
  
• FQC/PSI: final inspection to agreed AQL; carton drop/ISTA 3A where required.
  
• Deliverables: Inspection reports with photo/video evidence; rework logs; pass/fail summary.
  

Compliance, Lab & Documentation

• Arrange third-party labs for mandated tests; compile a digital compliance binder: test reports, certificates, traceability docs, MSDS (if applicable), COO, packing list, commercial invoice, VGM, fumigation/ISPM-15, etc.
  
• Deliverables: Compliance binder (download link), shipment pre-alert.
  

Logistics & Customs (EXW → DDP)

• Book lanes from the nearest port/ICD (Nhava Sheva, Mundra, Chennai, Tuticorin, Delhi ICD, etc.).
  
• Container stuffing supervision (photos, seal logs), insurance, customs clearance, final-mile if DDP.
  
• Deliverables: BL/AWB, broker instructions, tracking milestones, POD.
  

Scale-Up & Continuous Improvement

• Lock dual-source where strategic; implement OTIF ≥ 95%, RFT ≥ 98%, DPPM < 500 targets.
  
• Quarterly QBRs: cost downs (VA/VE), yield improvements, sustainability projects (energy, water, waste).
  

Category-Specific Checklists

Apparel & Textiles (cotton/MMF)

• Traceability: farm → gin → bale → spinner → knitter/weaver → dye/finish → CMT; documentation chain to avoid high-risk regions.
  
• Quality & Lab: GSM/tolerance, shrinkage, pilling, seam strength, colorfastness (wash/rub/light), azo/lead/formaldehyde; OEKO-TEX/GOTS where applicable.
  
• Finishing: handfeel/softeners, print/embellishment approvals; wash panels signed off.
  
• Typical SLAs: samples 7–12 days; bulk 35–60 days post-approval.
  

Metal Homewares & Décor (brass/steel/aluminum)

• Material: grade confirmation (e.g., SS 304/316), chemical composition (mill certs).
  
• Finish: plating thickness (µm) / powder-coat adhesion; corrosion (ASTM B117 salt-spray hours by spec).
  
• Safety/Compliance: lead/cadmium in surface coatings, REACH Annex XVII; food-contact where relevant (liner/lacquer compliance).
  
• Packaging: transit protection, carton ECT/BCT; ISTA 3A for retail/e-com.
  
• SLAs: samples 10–15 days; bulk 45–70 days.
  

Leather Goods & Footwear

• Materials: leather grade & tannage; Cr(VI) (ISO 17075), azo dyes, PCP; hardware plating tests.
  
• Fit/Build: last/size sets, stitch density, pull tests on straps/handles; outsole adhesion/flex.
  
• Social/chemical compliance (SEDEX/BSCI; RSL against brand list).
  
• SLAs: samples 12–18 days; bulk 45–75 days.
  

Auto/Engineering Components (castings/forgings/CNC/wiring)

• Process: APQP → PPAP (Level 3), control plan, MSA; torque/pressure/leak checks as needed.
  
• Materials & Certs: heat/lot traceability; IMDS (if automotive), RoHS (if electrical).
  
• Capability: GR&R, Cp/Cpk ≥ 1.33 on critical features; 100% inspection on safety-critical.
  
• SLAs: samples 21–35 days; bulk per takt (often 30–60 days).
  

Packaging (paper/board/rigid boxes)

• Board/Paper: GSM, ECT/Burst, Cobb, ply bonding; ink adhesion, rub tests.
  
• Print: color targets (Pantone), dielines, barcodes/labels, varnish/lamination spec.
  
• Transit: ISTA 1A/3A or retailer-specific protocols; unitized pallet optimization.
  
• SLAs: samples 7–10 days; bulk 15–30 days.
  

Governance & Risk Controls (so it stays de-risked)

• Contracts: NDA + Manufacturing Agreement with tooling ownership, IP protection, exclusivity by SKU/category if needed, and service-level penalties for OTIF/quality.
  
• Payments: TT / LC / mixed terms; escrow for tooling; FX hedging if multi-currency.
  
• RSL/ESG: Align to your restricted substance list; wet-process suppliers on ZDHC MRSL where applicable.
  
• Business continuity: second-source plan, safety stock rules, alternate ports, disaster playbook.
  
• Live visibility: shared dashboard with milestones (samples, audits, PSI, ETD/ETA), photo/video evidence, and digital document room.
  

Example Timeline (typical SKU)

• Week 0–1: Spec lock, longlist, HS/duty model
  
• Week 2: Audits + shortlist
  
• Weeks 2–4: Samples → Golden Sample
  
• Week 5: Pilot PO + FAI/PPAP (if engineered)
  
• Weeks 6–10: Bulk production with stage-gates
  
• Week 10+: PSI → ship (ocean) / Week 6+ if air
  

What you get from IndiaUnbox at each gate

• Gate Packs: Spec Pack, Audit Reports, Cost Sheets, Golden Sample Photos, AQL Plan, Lab Reports, Pilot Report, PSI Report, Shipment Dossier.
  
• Owners: One program manager; on-ground QC engineers; compliance lead.
  
• Outcome: Landed-cost parity (or better) with lower concentration risk, cleaner compliance, and audit-ready documentation.