Case Study: Custom Pinnable Half Body Mannequin for a Cycling Team in Malaysia
Source:Pinnable Half Body Mannequin /
Time:2026-09-18
Pinnable Half Body Mannequin for a Cycling Team in Malaysia
A Cycling Team approached us with a pinnable half body mannequin requirement for Malaysia. 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
- Inconsistent sizing between production runs
- No reliable way to track a order once it enters production
- Suppliers who disappear once the deposit is paid
What we specified
| Product | Pinnable Half Body Mannequin |
|---|---|
| Client type | A Cycling Team |
| Market | Malaysia |
| Order volume | 8,000 pieces across 6 colourways |
| Base fabric | Neoprene |
| Decoration | Heat Transfer Printing |
| Size range | Custom grading |
| Sampling rounds | 3 |
| Delivery window | 8 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Neoprene and locked shrinkage allowance before grading.
- Decoration was moved to Heat Transfer Printing 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
- 8,000 pieces delivered inside the 8-week window.
- Unit cost held within 2.0% of the original quotation.
- Return rate linked to fit or workmanship stayed under 0.5%.
- 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?
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