Case Study: Custom Reverse Coil Zipper for a Supermarket Own-Brand Team in Indonesia

Reverse Coil Zipper for a Supermarket Own-Brand Team in Indonesia

A Supermarket Own-Brand Team approached us with a reverse coil zipper requirement for the Indonesia 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
• Reorders that quietly changed supplier and changed the hand feel
• Lead time quoted without the plating or dyeing sub-process

What we specified

How it was resolved

1. We rebuilt the specification around POM Plastic and locked the tolerance before bulk.
2. The finish was moved to Glossy Enamel Coating after strike-off tests showed better durability.
3. A pre-production sample was approved and retained as the golden reference.
4. Production ran with in-line inspection and a mid-run photo report.
5. Cartons were packed to the client's own barcode and ratio specification.

Result

• 100,000 pieces delivered inside the 4-week window.
• Unit cost held within 3.0% 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?

Share the programme details and we will propose two alternatives — one optimised for unit cost, one for lead time — and let you choose.