The Valve That Finally Passed the First Time

Theme: Leak-free ramp; simple test jig; first-pass up
Cluster/Port: Coimbatore/Rajkot → Tuticorin/Mundra

A European distributor had a painful pattern: perfectly good parts that only passed the pressure test after rework. Shipments hesitated, costs crept up, and confidence slipped.

We paired them with a foundry-machining combo and drew a clear path: small pilot lots, a shared “first-article” pack everyone could agree on, and a straightforward pressure test jig with go/no-go criteria. The factory teams tuned their process; we kept the dates, photos, and mid-run checks steady—and booked an independent verification so the buyer could say “go” without a debate.

What changed: the first-pass pressure pass rate climbed to ~99%, rework bins emptied, and weekly shipments resumed without fire drills.
Our role: shortlist, schedule, independent test & QC, tidy evidence. Factory role: make the adjustments and hold the spec.

Two Shops, One Rhythm

Theme: Casting → machining flow smoothed; lead time ↓ ~25%
Cluster/Port: Rajkot/Coimbatore → Mundra/Tuticorin

Great castings. Great machining. But the hand-off between the two created a queue that ate calendar days. Parts waited for a truck; a few came back for touch-ups; the “ready to ship” date kept sliding.

We didn’t redesign the part—we reframed the week. Both suppliers agreed to a simple, shared rhythm: fixed pick-up days, small balanced lots, and a short checklist at hand-off so surprises didn’t travel. We added a quick mid-week visual check at the machine shop and a pre-booked inspection before packing.

What changed: total lead time dropped about 25%, on-time delivery steadied, and the buyer stopped paying for last-minute expedites.
Our role: align two suppliers, lock the calendar, set hand-off checks, book PSI. Factory role: keep the flow and finish on the beat.

The Price That Made Sense End-to-End

Theme: Should-cost win; BOM teardown & renegotiation (−8–12%)
Cluster/Port: Coimbatore/Rajkot → Tuticorin/Mundra

Ex-factory pricing looked fine—but the landed number never did. Freight, finishes, and little add-ons kept nudging it over the target.

We helped the buyer and supplier see the same picture: a simple should-cost view that separated material, processing, finish, packing, and freight. With that on the table, the factory suggested sensible swaps (e.g., pack counts, finish steps where appearance allowed), and we negotiated around realistic volumes and a cleaner shipping plan.

What changed: unit cost came down ~8–12% with no change to form, fit, or function. The supplier kept margin via better flow; the buyer hit the price they needed.
Our role: bring cost transparency, align options, handle the renegotiation & route tweaks. Factory role: implement the chosen plan.