Case Study: Custom Bra Underwire for a Workwear Distributor in Kenya
Source:Yard Art Wind Spinners /
Time:2026-09-18
Bra Underwire for a Workwear Distributor in Kenya
A Workwear Distributor approached us with a bra underwire requirement for the Kenya 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
- Lead time quoted without the plating or dyeing sub-process
- Shrinkage that only showed up after the first wash
- Elastic that lost recovery after three washes
What we specified
| Item | Bra Underwire |
|---|---|
| Client type | A Workwear Distributor |
| Market | Kenya |
| Order volume | 50,000 pieces across 4 specifications |
| Base material | Ceramic |
| Standard size | 15 mm Width |
| Finish | Yarn-Dyed Finish |
| Sampling rounds | 2 |
| Delivery window | 4 weeks from PO to ex-factory |
| Compliance | AATCC Test Methods |
How it was resolved
- We rebuilt the specification around Ceramic and locked the tolerance before bulk.
- The finish was moved to UV Printing 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
- 50,000 pieces delivered inside the 4-week window.
- Unit cost held within 3.0% 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
Fix the specification count early. Adding variants after production starts is the most expensive change a client can request.
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.
