- Client: A US-based reputed valve manufacturer
- Industry: Flow Control
- Challenge: Bringing a variant that combined two of their products to enhance the market reach by offering specific features with an attractive target price and expanding the solution offerings.
- Finding the right manufacturer with R&D and prototyping capabilities
- Meeting US compliance and safety standards – API 641, etc
- Keeping production costs competitive without compromising quality
- Scaling quickly from pilot runs to large-volume production
TES Global’s Approach
Our team worked with the client’s production, quality and sourcing team to identify a team of designers and transition the design to a pilot product. We achieved success after several iterations and improvements that was born out of the process.
1. Product Design Support
- Reviewed the client’s initial concept and collaborated with industrial designers.
- Recommended design adjustments to improve manufacturability and durability.
- Shared insights on material selection and cost implications.
2. Supplier Identification & Vetting
- Worked with our existing manufacturer and conducted detailed factory audits covering compliance, capacity, and quality systems.
- Negotiated initial agreements to secure competitive terms for prototyping.
3. Pilot Development
- Oversaw creation of CAD models, 3D-printed prototypes, and functional samples.
- Coordinated rapid prototyping iterations until the product met performance requirements.
- Supervised laboratory testing for compliance with standards.
4. Mass Production Readiness
- Managed a small-batch pilot run to validate production efficiency and quality consistency.
- Implemented multi-stage quality inspections: incoming raw materials, in-process, and final pre-shipment checks.
5. Packing Philosophy
- Assisted to our manufacturing partners -to achieve the highest standard of attractive packing with economical approach.
6. Quality Certifications:
- Worked with certification bodies to obtain API 641, Fire safe certifications for global markets.
7. Mass Production & Logistics
- Scaled production to 10000 units within the first year.
- Coordinated end-to-end logistics, ensuring on-time delivery to the client
- Maintained ongoing supplier relationship for continuous cost optimization and product improvements.
The Results
- Reduced time-to-market from 18 months (industry average) to 12 months
- Achieved 30% cost savings compared to initial US-based prototyping estimates
- Secured compliance with standards, ensuring smooth entry into the global market
- Successfully scaled to mass production, enabling the client to meet retail launch deadlines
Client Feedback
“TES Global was more than a sourcing company—they became an extension of our team. From helping us refine our product design to managing every detail of manufacturing and logistics, they gave us the confidence to launch on time and at scale. We couldn’t have done it without them.” — GM, Valve Manufacturer, USA
Conclusion
This project demonstrates how TES Global goes beyond sourcing—acting as a true partner in innovation. By combining technical expertise, supplier networks, and strict quality control, we helped our client transform an idea into a successful, market-ready product.
Looking to bring your next product idea to life? Contact TES Global today and let’s build your success together.
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