Case Study: Custom Aglet for a Footwear Factory in South Korea
Source:Magnetic Whiteboard Planners /
Time:2026-09-18
Aglet for a Footwear Factory in South Korea
A Footwear Factory approached us with a aglet requirement for the South Korea market. The brief was specific: a defined look, a hard launch date and a unit cost that had to survive freight and duty. This case study records what was specified, what went wrong in sampling and how the bulk order was delivered.
The challenge
- A zipper puller that broke under pull test at the warehouse
- Lead time quoted without the plating or dyeing sub-process
- Reorders that quietly changed supplier and changed the hand feel
What we specified
| Item | Aglet |
|---|---|
| Client type | A Footwear Factory |
| Market | South Korea |
| Order volume | 100,000 pieces across 3 specifications |
| Base material | Ceramic |
| Standard size | 38 mm Width |
| Finish | Glossy Enamel Coating |
| Sampling rounds | 4 |
| Delivery window | 10 weeks from PO to ex-factory |
| Compliance | ISO 14001 |
How it was resolved
- We rebuilt the specification around Ceramic and locked the tolerance before bulk.
- The finish was moved to Piece-Dyed Finish after strike-off tests showed better durability.
- A pre-production sample was approved and retained as the golden reference.
- Production ran with in-line inspection and a mid-run photo report.
- Cartons were packed to the client's own barcode and ratio specification.
Result
- 100,000 pieces delivered inside the 10-week window.
- Unit cost held within 2.0% of the original quotation.
- Inspection-related rejection stayed under 1.0%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Keep one accountable owner on both sides. Most delays come from hand-offs, not from machines.
Planning something similar?
Tell us the item, the quantity and the delivery window. We will quote it with the sub-processes named, so the lead time you approve is the lead time you get.
