Case Study: Custom Horn Button for a Logistics Company in New Zealand
Source:Retro Sunglasses /
Time:2026-09-18
Horn Button for a Logistics Company in New Zealand
A Logistics Company approached us with a horn button requirement for the New Zealand 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
- MOQ that was quoted per colourway rather than per style
- Elastic that lost recovery after three washes
- Cartons packed to the factory ratio instead of the buyer's size ratio
What we specified
| Item | Horn Button |
|---|---|
| Client type | A Logistics Company |
| Market | New Zealand |
| Order volume | 100,000 pieces across 2 specifications |
| Base material | Nickel Silver |
| Standard size | 10# Gauge |
| Finish | Piece-Dyed Finish |
| Sampling rounds | 4 |
| Delivery window | 8 weeks from PO to ex-factory |
| Compliance | REACH SVHC Screening |
How it was resolved
- We rebuilt the specification around Nickel Silver and locked the tolerance before bulk.
- The finish was moved to Powder 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
- 100,000 pieces delivered inside the 8-week window.
- Unit cost held within 2.0% 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
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.
