Case Study: Custom Closed-End Zipper for a Footwear Factory in Singapore

Closed-End Zipper for a Footwear Factory in Singapore

A Footwear Factory approached us with a closed-end zipper requirement for the Singapore 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 trim that passed sampling but failed in-line because it was never cycle tested
• Shade drift between the approved lab dip and the bulk lot
• Cartons packed to the factory ratio instead of the buyer's size ratio

What we specified

How it was resolved

1. We rebuilt the specification around Copper and locked the tolerance before bulk.
2. The finish was moved to Powder 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

• 10,000 pieces delivered inside the 6-week window.
• Unit cost held within 1.5% of the original quotation.
• Inspection-related rejection stayed under 2.0%.
• 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.