🇦🇺Australia

Lost Contracts from Delayed FAI Approvals

2 verified sources

Definition

FAI approval is required to start series production; failures or delays in plastics manufacturing lead to idle equipment and lost sales opportunities with OEM buyers.

Key Findings

  • Financial Impact: AUD 20,000-100,000 per delayed contract (lost revenue from 2-4 week production halts)
  • Frequency: Per major client order (1-4 times/year)
  • Root Cause: Manual FAIR documentation, non-conformance resolution delays, poor change tracking

Why This Matters

The Pitch: Plastics suppliers in Australia 🇦🇺 forfeit AUD 50,000+ deals annually due to FAI delays. Digital FAI workflows secure approvals 50% faster.

Affected Stakeholders

Sales Managers, Account Executives, Project Managers

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Financial Impact

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Current Workarounds

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Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

Cost of Poor Quality

AUD 20,000-100,000/year in material waste and rework (2-5% of production costs for mid-sized firm)

Waste from Trial-and-Error

AUD 10,000-50,000/year in scrapped materials and labor (1-3% of material costs)

Capacity Loss from Rework

AUD 15,000-60,000/year (40 hours/month downtime at AUD 100/hour machine rate)

PPAP-Bottlenecks und Freigabe-Verzögerungen

Logikbasiert: ca. AUD 50.000–150.000 entgangener Umsatz pro Jahr durch 1–2 Monate verspätete Serienfreigaben infolge unvollständiger/fehlerhafter PPAP-Sets; zusätzlich ca. 40–80 Maschinenstunden/Jahr ungenutzte Kapazität pro kritischem Projekt.

Überhöhte PPAP-Bearbeitungskosten und Doppelarbeit

Logikbasiert: ca. 400–1.000 zusätzliche Arbeitsstunden pro Jahr für manuelle PPAP-Dokumentation und Nacharbeit, entsprechend rund AUD 20.000–60.000 Personalkosten p.a. in einem typischen mittelgroßen Kunststoffwerk mit PPAP-pflichtigen Kunden.

Kundenabwanderung durch nicht bestandene oder verspätete PPAPs

Logikbasiert: ca. 5–15 % des PPAP-pflichtigen Jahresumsatzes gefährdet; bei einem typischen Umsatz von AUD 4 Mio. mit Automotive- und ähnlichen Kunden entspricht das ca. AUD 200.000–600.000 potenziell verlorenem oder nicht gewonnenem Umsatz pro Jahr.

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