Case Study: Custom Full Body Kid Mannequin for a Professional Sports Club in Japan
Source:Full Body Kid Mannequin /
Time:2026-09-18
Full Body Kid Mannequin for a Professional Sports Club in Japan
A Professional Sports Club approached us with a full body kid mannequin requirement for Japan. 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
- Long lead times that miss the selling season
- Minimum order quantities far above what a growing brand can absorb
What we specified
| Product | Full Body Kid Mannequin |
|---|---|
| Client type | A Professional Sports Club |
| Market | Japan |
| Order volume | 500 pieces across 4 colourways |
| Base fabric | Cashmere |
| Decoration | Screen Printing |
| Size range | XS-3XL |
| Sampling rounds | 3 |
| Delivery window | 5 weeks from PO to ex-factory |
How it was resolved
- We rebuilt the tech pack around Cashmere and locked shrinkage allowance before grading.
- Decoration was moved to Screen 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
- 500 pieces delivered inside the 5-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?
Tell us the quantity, target price and delivery window, and we will build a customisation programme around those three numbers.
