Case Study: Custom Cord Stopper for a Hat and Cap Producer in Singapore

Cord Stopper for a Hat and Cap Producer in Singapore

A Hat and Cap Producer approached us with a cord stopper 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

• Reorders that quietly changed supplier and changed the hand feel
• A zipper puller that broke under pull test at the warehouse
• Lead time quoted without the plating or dyeing sub-process

What we specified

How it was resolved

1. We rebuilt the specification around Nickel Silver and locked the tolerance before bulk.
2. The finish was moved to Epoxy Doming 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 6-week window.
• Unit cost held within 4.5% 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

Fix the specification count early. Adding variants after production starts is the most expensive change a client can request.

Planning something similar?

Send the reference sample or tech pack and we will come back with a costed specification, a sampling timetable and the compliance documents your market requires.