Dual-source without drama: RFQ → T1/T2 → PPAP/FAI → pilot → ramp & consolidation.
Chips: 90-day plan • Gate checklist • Exit criteria

What this page does

A clear path to move or dual-source SKUs from China to India—fast, controlled, and measurable. Use our 90-day blueprint, pass/fail gates, and exit criteria to de-risk your shift while hitting cost and lead-time targets.
CTAs: Start China+1 RFQ (24–72h shortlist) • Book Factory Audit / PPAP Pack

The 90-Day Plan (visual timeline)

Days 0–7 — RFQ & Shortlist
Inputs locked, NDAs signed. 2–3 vetted suppliers, capability match, should-cost check.

Days 8–20 — T1 Samples (Fit/Finish/Form)
Soft tooling (if needed), baseline process sheet, initial measurement report, pack test.

Days 21–35 — T2/T3 Samples (Function & Stability)
Process tweaks, CTF/CTQ alignment, reliability checks, lab tests if required.

Days 36–50 — PPAP/FAI
Control plan, PFMEA, process capability (where applicable), First Article Inspection sign-off.

Days 51–70 — Pilot Run (Pre-Ramp)
500–2,000 pcs (category-dependent). DUPRO checks, yield tuning, logistics dry-run.

Days 71–90 — Ramp & Dual-Source Stabilization
Batch production at agreed MOQ, PSI, on-time shipping. Decision review for consolidation.

Gate Checklist (Go / Hold / Fix)

Gate 1: Post-Shortlist (Day 7)

• Factory audit score ≥ 80/100 (capability + compliance)
  
• Cost band within ±10% of should-cost
  
• Sample & tooling calendar committed
  

Gate 2: T1 Approval (Day 20)

• Dimensional pass on A-surfaces (≥ 98% within spec)
  
• Visual defects ≤ AQL 1.0 critical / 2.5 major
  
• Pack/drop test pass; draft control plan agreed
  

Gate 3: T2/T3 (Day 35)

• Functional pass under operating conditions
  
• Lab compliance (e.g., REACH/CPSIA/EN) if applicable
  
• Agreed corrective actions closed with evidence
  

Gate 4: PPAP/FAI (Day 50)

• FAI signed; PFMEA ≥ Rank 7 actions addressed
  
• Cp/Cpk ≥ 1.33 on CTQs (where statistically relevant)
  
• Golden sample sealed; master drawings & COA ready
  

Gate 5: Pilot Run (Day 70)

• First-pass yield (FPY) ≥ 95%
  
• DUPRO defect rate ≤ 1.5% major
  
• Logistics simulation: label/docs/HS verified
  

Gate 6: Ramp Review (Day 90)

• OTD ≥ 95%; DPPM ≤ 1,500 (category-dependent)
  
• Landed cost within +5% of target or savings case documented
  
• Supplier capacity & second-shift readiness confirmed
  

Download: Gate Checklist (PDF) • PPAP/FAI Pack (Sample)

Roles & RACI (who does what)

• Buyer (You): Specs, approvals, risk acceptance, PO release.
  
• IndiaUnbox: RFQ engine, audits, sample program, PPAP/FAI orchestration, QC (DUPRO/PSI), logistics handover.
  
• Supplier: Tooling, production, CAPA, documentation.
  
• Accredited Lab (if needed): Compliance testing & COAs.
  

Exit Criteria (Consolidate, Continue Dual-Source, or Roll Back)

Choose one after the Day-90 Review:

Consolidate to India if:

• 2 consecutive lots hit OTD ≥95%, DPPM ≤ target, and landed cost ≤ target.
  
• PPAP/FAI docs complete; capacity buffer ≥ 1.5× average monthly demand.
  

Maintain Dual-Source if:

• KPIs met but supply risk (tier-2 materials, seasonality) remains > medium.
  
• You want strategic price tension and redundancy.
  

Roll Back / Re-Pilot if:

• Two or more gates missed without credible CAPA, or compliance fails persist.
  
• Total landed cost variance > +10% without viable cost-down path.
  

Download: Exit Decision Matrix (XLS)

Risk Controls (built into the plan)

• Tooling: clone vs. move decision, 3D scan & recut option, custody log.
  
• Tier-2 Materials: dual-source critical inputs (resins, trims, coatings).
  
• Seasonality: India holiday/monsoon buffers; alternate port routing.
  
• Quality: golden sample library, sealed; PPAP level matched to risk.
  
• Logistics: label/data templates, HS pre-classification, DDP preview.
  

What you receive (deliverables)

• Shortlist compare sheet • Audit report & CAPA
  
• T1/T2/T3 reports with photos & dimensional data
  
• PPAP/FAI dossier (incl. control plan, PFMEA, PSW where used)
  
• DUPRO/PSI QC reports (24–48h turnaround)
  
• Pilot & ramp run dashboards (FPY, OTD, DPPM)
  

Micro FAQ

Can this finish in under 90 days?
Yes, for non-tooled SKUs and simple finishes; compress T1/T2 and pull-ahead PPAP documents.

Do all categories need PPAP?
No—use PPAP-lite/FAI for non-automotive; keep control plan + FAI mandatory.

What batch size for pilot?
Enough to stress real flow (typically 10–20% of a full lot or 500–2,000 pcs).

Page layout (for your dev)

• Hero: “Transition Blueprint (Pilot → Ramp)” + subtext + chips + Start China+1 RFQ button
  
• Timeline strip: 6 stages with icons and day ranges
  
• Gate accordion: Gate 1–6 with Go/Hold/Fix badges + download links
  
• Right rail: RACI card • Risk controls • “Book Factory Audit / PPAP Pack” sticky CTA
  

Primary CTAs: Start China+1 RFQ (24–72h shortlist) • Book Factory Audit / PPAP Pack • Download Gate Checklist