Case Study: Custom Bamboo Fabric for a Theatre Costume Workshop in Indonesia
Source:Antique Hand Painted Screen /
Time:2026-09-18
Bamboo Fabric for a Theatre Costume Workshop in Indonesia
A Theatre Costume Workshop approached us with a bamboo fabric 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
- A compliance document that arrived after the goods were already shipped
- Cartons packed to the factory ratio instead of the buyer's size ratio
- Shade drift between the approved lab dip and the bulk lot
What we specified
| Item | Bamboo Fabric |
|---|---|
| Client type | A Theatre Costume Workshop |
| Market | Indonesia |
| Order volume | 20,000 pieces across 3 specifications |
| Base material | Acrylic |
| Standard size | 160 gsm |
| Finish | Black Nickel Finish |
| Sampling rounds | 2 |
| Delivery window | 5 weeks from PO to ex-factory |
| Compliance | California Prop 65 |
How it was resolved
- We rebuilt the specification around Acrylic 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
- 20,000 pieces delivered inside the 5-week window.
- Unit cost held within 4.5% 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
Fix the specification count early. Adding variants after production starts is the most expensive change a client can request.
Planning something similar?
Tell us the item, the quantity and the delivery window. We will quote it with the sub-processes named, so the lead time you approve is the lead time you get.
