The Challenge
Tight Window. High Stakes.
Our customer — a Tier 1 supplier serving a major automotive OEM — was preparing for a vehicle program launch and needed a partner who could ramp production fast. They had a validated prototype harness, but their previous supplier was unable to scale to the required volumes within the launch timeline.
The challenge was twofold: match the validated prototype exactly, and deliver production-ready documentation that aligned with the OEM's PPAP submission requirements. Any slip in either would mean missed launch milestones.
"We needed someone who could move at the speed of an automotive launch — without us having to babysit the process." — Procurement Lead, Tier 1 Supplier
Our Approach
A Four-Step Path
to Production.
We worked closely with the customer's engineering team from day one — not as a vendor, but as a production partner accountable for the launch.
Reviewed the validated prototype build documentation, identified production-readiness improvements, and confirmed material availability.
Built a small pre-production batch for customer validation and to lock in fixturing, tooling, and process documentation.
Compiled production part approval documentation including FAI reports, material certifications, and process validation data.
Scaled to full production volumes within six weeks of approval, with weekly delivery cadence aligned to the customer's assembly schedule.
Results
A Successful Program Launch.
- Reached full production volume of 5,000+ units per month within 6 weeks of program approval
- Delivered complete PPAP submission documentation with no rejections
- Maintained 100% USA-made compliance for the customer's domestic content requirements
- Established weekly delivery cadence aligned to assembly line schedule
- Zero quality escapes through first six months of production
- Now in ongoing production as a long-term supplier on this and follow-on programs
Why It Mattered
More Than a Supplier.
For a Tier 1 supplier, missing a launch window isn't just an inconvenience — it's a financial and reputational hit with their OEM. By treating their program like our own, we became more than a wire harness vendor. We became part of their launch team.
Today, this customer continues to use us for ongoing production on multiple programs, and we've grown into a long-term partner for new vehicle launches.