Case Study: Custom Full Body Kid Mannequin for an Airline Catering Team in Thailand
Source:Full Body Kid Mannequin /
Time:2026-09-18
Full Body Kid Mannequin for an Airline Catering Team in Thailand
An Airline Catering Team approached us with a full body kid mannequin requirement for Thailand. The brief was specific: a defined look, a hard launch date and a unit cost that had to survive shipping and duty. This case study records what was specified, what went wrong in sampling and how the bulk order was delivered.
The challenge
- No reliable way to track a order once it enters production
- Long lead times that miss the selling season
- Color drift between lab dips and bulk fabric
What we specified
| Product | Full Body Kid Mannequin |
|---|---|
| Client type | An Airline Catering Team |
| Market | Thailand |
| Order volume | 1,200 pieces across 3 colourways |
| Base fabric | Combed Cotton |
| Decoration | Quilting |
| Size range | XS-3XL |
| Sampling rounds | 4 |
| Delivery window | 12 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Combed Cotton and locked shrinkage allowance before grading.
- Decoration was moved to Quilting after strike-off tests showed better wash 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 size ratio specification.
Result
- 1,200 pieces delivered inside the 12-week window.
- Unit cost held within 2.0% of the original quotation.
- Return rate linked to fit or workmanship stayed under 1.0%.
- The specification is now on file, so reorders reproduce the approved sample.
What we would repeat
Keep one process owner on both sides. Most delays come from hand-offs, not from machines.
Planning something similar?
Share a reference photo or a sample garment and we will reverse-engineer the specification for your own label.
