1,100-plot housing scheme, two keys per handover

The builder had been buying door hardware from three suppliers, and every handover pack contained a bag of unmatched keys.

What we consolidated

Six SKUs cover the whole plot: an entry handleset and matching deadbolt on the front door, a heavy-duty entry lever on the back and garage doors, privacy levers on bedrooms and bathrooms, passage levers on corridors, and dummy trim on wardrobes. All six in one finish, from one process run.

Keying

Every exterior lock on a plot keyed alike as one group, with three keys per plot supplied. Construction keying let trades work the site for eight months on a site key that voided itself the first time the homeowner turned theirs.

Packing

Packed by plot rather than by model — one carton per house, labelled with the plot number, so the site foreman stopped sorting hardware on a trestle table.

Result

Handover packs went from eleven keys to two, and hardware-related callbacks fell to 0.3% of plots across the first phase.