Case Study: Custom Woven Patch for a Theatre Costume Workshop in Indonesia
Source:Quilling Paper Strips /
Time:2026-09-18
Woven Patch for a Theatre Costume Workshop in Indonesia
A Theatre Costume Workshop approached us with a woven patch 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
- Shade drift between the approved lab dip and the bulk lot
- A spec that lived in an email instead of a tech pack
- An interlining that bubbled after the first press
What we specified
| Item | Woven Patch |
|---|---|
| Client type | A Theatre Costume Workshop |
| Market | Indonesia |
| Order volume | 2,000 pieces across 6 specifications |
| Base material | Ceramic |
| Standard size | 25 mm Width |
| Finish | Matte Black Coating |
| Sampling rounds | 2 |
| Delivery window | 6 weeks from PO to ex-factory |
| Compliance | WRAP |
How it was resolved
- We rebuilt the specification around Ceramic and locked the tolerance before bulk.
- The finish was moved to Glossy Enamel Coating 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
- 2,000 pieces delivered inside the 6-week window.
- Unit cost held within 3.0% of the original quotation.
- Inspection-related rejection stayed under 0.5%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Approve a pre-production sample made from the actual bulk base material. Substitute material behaves differently in finishing.
Planning something similar?
If you are comparing suppliers, send us the spec they quoted against. We will quote the same spec and show you where the difference sits.
