A polo shirt seems like a simple garment. Fabric, a collar, a placket, a few buttons. Not much room for things to go wrong.
Then a shipment of 8,500 polos showed up at our customer’s distribution center with orange buttons sewn on, when the order called for white — opaque, not a shade of off-white, not “close enough.” Just wrong.
Our customer ran a simple AQL audit on the shipment upon arrival, and it didn’t take long for them to realize something was really wrong.
Nobody notices a button until it’s the wrong one. Then it’s the only thing anyone sees. A retail buyer isn’t accepting a shipment of polos with the wrong hardware on them, and shipping them back overseas to get fixed was out of the question. The polos had to be on shelves in two weeks.
The retailer called Darn It! and had a box of 20,000 correct buttons overnighted to our facility.
We received the shipment, picked every orange button off by hand, and resewed the correct white buttons across all 8,500 units. Every shirt went back through inspection before it shipped, so the only thing anyone saw on the rack was a normal white button, exactly where it was supposed to be.
The project took two weeks, start to finish.
If a small detail slipped through on your last shipment, that’s exactly the kind of call we like to get.
“Your Problem Is Our Business”
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