Launching a New B2C Roof Rack Range Through Offshore Design and Supply Transformation
Client Profile
An established automotive accessory supplier with a strong B2B legacy, looking to reposition for the direct-to-consumer (D2C) market.
Challenge
The client faced several strategic and operational challenges:
Reliance on local and Chinese suppliers no longer aligned with cost and flexibility goals
Existing range was designed for factory installation, not self-fit retail
No suitable packaging or branding for the D2C channel
Needed a fully re-engineered product line, including packaging and user experience
Required a dependable long-term supplier outside China
Solution
- Novex applied its Supply Focused Methodology to create and deliver a complete, consumer-ready product solution:
- Identified and onboarded a high-capability Indian manufacturing partner
- Redesigned the range from the ground up for self-installation and online retail
- Specified and sourced plastic mouldings, including tooling for all injection-moulded components
- Delivered complete kits, with all aluminium profiles, stainless steel fasteners, and instruction packs
- Developed new packaging designs and outer cartons aligned to the client’s brand strategy
- Managed all finish development — from anodising to powder coating
Product Features
- Modular system available in kit and individual form
- Engineered for DIY installation with standard tools
- Rigid outer packaging, clear installation guides, and retail-ready branding
- Stainless steel fixings and corrosion-resistant surface finishes
- All plastic components designed in-house and produced using dedicated tooling
Full Project Timeline
- Full Project Duration:
~25 Weeks
(Slightly extended due to bespoke plastic tooling and detailed prototype iteration) - Stages 1–2 (Opportunity & Design Strategy)
~2 weeks
Identified supply gaps, confirmed D2C requirements, and defined kit architecture. - Stages 3–4 (Prototype & Finalisation)
~12 weeks
Developed CAD, sourced aluminium profiles, commissioned plastic tooling, and produced complete kits for review. Extensive testing of fit, finishes, and packaging. - Stages 5–6 (Sourcing & Delivery Planning)
~6 weeks
Finalised supplier audits, tooling approval, and coordinated full pre-production samples. - Stages 7–8 (Commercial & Handover)
~5 weeks
Locked in supply terms, delivered tech packs, shipping guides, and prepared first full production runs.
Ongoing Execution
- From Stage 9 onward, Novex remains responsible for:
- All international freight, customs clearance, and importing
- Coordinating demand planning and reorders
- Managing any packaging updates, SKU extensions, or brand iterations
- Liaising with tooling maintenance and future plastic component updates
Results
- New Range Launched: A high-quality, self-fit aluminium roof rack product line with full retail packaging
- All-in-One Kits: Each kit includes stainless steel fasteners, plastic mouldings, and clear fitting instructions
- Strategic Supply Shift: Replaced China and local sources with reliable Indian partner
- Cost Efficiency: Competitive landed cost with greater margin flexibility
- Business Value: $250,000+ expected in year one, with upward momentum
- Customer Feedback: “Great quality and surprisingly easy to fit”
- Sales Team Feedback: High confidence due to brand exclusivity and no direct comparison in the market
Conclusion
This project is a clear example of Novex’s end-to-end capability — from design and tooling to sourcing and ongoing delivery. In just 25 weeks, the client moved from legacy supply reliance to a robust, scalable B2C model with differentiated product, brand presence, and higher-margin returns.