Introduction
This case study details how a potential quality disaster with a custom color-blocked sports bra was transformed into an opportunity to demonstrate deep technical expertise. By rapidly diagnosing a complex chemical issue and implementing a science-based solution, Sansansun not only solved the problem but also solidified a long-term, trust-based partnership with a European client.
Client Profile: A Custom Color-Blocked Design
A European client placed an order for a custom black and white color-blocked yoga bra, a stylish piece that utilized a custom fabric combination from our factory. The client was highly satisfied with the overall design and the pre-production sample, and was ready to move forward with the bulk order.
The Challenge: An Unexpected Failure in the Client’s Wash Test
After receiving the pre-production sample, the client conducted their own standard internal testing. Using a BEKO washing machine at a 40°C standard program, they discovered a critical issue: the dye from the black fabric had bled into the white portion, causing significant color transfer. This was a serious risk that made the product unacceptable for their retail standards and jeopardized the entire upcoming launch.
The Solution: A Rapid, Science-Based Investigation
We treated the issue with the highest urgency and transparency. Our response was immediate and methodical:
- Immediate Cross-Functional Review: We instantly convened an emergency meeting with our production department, QC department, and the fabric supplier to analyze the problem together.
- Expert Root Cause Analysis: Our technical team quickly provided a professional explanation: the acid-based dye originally used was reacting with the alkaline water common in the client’s region, causing the color bleeding.
- Third-Party Verification: To validate our findings, we collaborated with a third-party testing lab (like SGS) to conduct tests on the fabric under different pH conditions, confirming the root cause.
- Rapid Re-engineering & Campionamento: We quickly implemented a solution, switching to an alkaline-compatible dye to reproduce the fabric. A new sample was produced and sent to the client for re-testing in a very short timeframe.
The Outcome: A Stronger Product and a Deeper Partnership
The new sample passed the client’s re-test perfectly, with zero color bleeding. The client expressed high praise for our rapid response, professional analysis, and effective problem-solving capabilities. They confirmed that a factory demonstrating such a proactive and capable attitude when facing problems is a partner worth keeping for the long term. This incident, which began as a crisis, ultimately served to deepen our partnership and build a stronger foundation of trust.
