Case Study: Custom Kids Gym Fitness Set for a Film Production House in Mexico
Source:Kids Gym Fitness Set /
Time:2026-09-18
Kids Gym Fitness Set for a Film Production House in Mexico
A Film Production House approached us with a kids gym fitness set requirement for Mexico. 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
- Packaging that arrives crushed and unsellable
- Inconsistent sizing between production runs
- Color drift between lab dips and bulk fabric
What we specified
| Product | Kids Gym Fitness Set |
|---|---|
| Client type | A Film Production House |
| Market | Mexico |
| Order volume | 800 pieces across 2 colourways |
| Base fabric | Cashmere |
| Decoration | All-Over Sublimation |
| Size range | XS-3XL |
| Sampling rounds | 2 |
| 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 All-Over Sublimation 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
- 800 pieces delivered inside the 5-week window.
- Unit cost held within 4.5% 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?
Book a 20-minute call with our merchandising team and get a written quotation within 48 hours.
