Case Study: Custom High Underwear for a Public School District in the United States

High Underwear for a Public School District in the United States

A Public School District approached us with a high underwear requirement for the United States. 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

• Long lead times that miss the selling season
• No reliable way to track a order once it enters production
• Suppliers who disappear once the deposit is paid

What we specified

How it was resolved

1. We rebuilt the tech pack around Pima Cotton and locked shrinkage allowance before grading.
2. Decoration was moved to Hangtag and Packaging after strike-off tests showed better wash 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 size ratio specification.

Result

• 2,000 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 1.5%.
• The specification is now on file, so reorders reproduce the approved sample.

What we would repeat

Fix the size ratio early. Changing the ratio after cutting starts is the single most expensive change a client can request.

Planning something similar?

Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.