Introduction:
A mid-size fashion brand in Denmark was struggling with rising production costs. Their costs had gone over budget by 20%, adding an extra $25,000 to each production run. This increase was mostly due to inconsistent materials and inefficient manufacturing processes with their supplier in Bangladesh. The Danish brand turned to NoName, an experienced clothing manufacturer in India, for help.
In one production cycle, NoName reduced their cost by 40%, turning a $25,000 overrun into $10,000 in savings. NoName achieved this $35k impact by finding better material suppliers, improving quality control, and streamlining the production process for the brand.
In this case study, we will explore how NoName helped this Danish fashion brand overcome these obstacles and grow their business successfully.
The Challenge: Costs Out of Control
The Danish fashion brand was facing financial strain due to their rising production costs. As a mid-size fashion brand making about 10,000 garments each season, their profit margins were tight. Any unexpected costs could hurt their ability to stay competitive in the fashion industry.
They found themselves spending 20% more than planned on production, which added $25,000 to their expenses each cycle. These higher costs were caused by fluctuations in material prices and problems in the production process. The suppliers in Bangladesh sourced fabrics from different vendors, which caused inconsistencies in quality, color, and fabric texture. This resulted in poor-quality garments that often needed to be fixed or couldn’t be sold.
NoName’s Solution: Fixing the Core Problem
The Danish brand reached out to NoName, a clothing manufacturer in India that specializes in helping small to mid-sized fashion brands. NoName quickly identified that the main issue was with the materials being used. They suspected the inconsistent fabric quality was causing the rising costs and other production issues.
To confirm this, NoName tested 8-10 samples of the materials from the Bangladeshi suppliers at SGS, a globally recognized testing lab. The results revealed that while the fabrics had the same basic composition, their quality varied greatly. Differences in color absorption, shrinkage, and fabric texture led to inconsistent and poor-quality garments. These problems were causing high defect rates and increasing production costs.
Step 1: Sourcing High-Quality Fabrics from India
After discovering the issue, NoName emphasized to the Danish fashion brand the importance of working with consistent, high-quality fabric suppliers. They explained that even skilled manufacturers couldn’t fix problems caused by poor materials. Without reliable fabric, the same issues would keep occurring.
NoName used their network of trusted fabric suppliers in India to source better-quality fabrics that matched the brand's design and quality standards. This ensured that all garments were made with consistent materials, eliminating the quality issues that had been causing defects and delays.
Step 2: Reducing Defects in Production
With the new fabric suppliers in place, the production quality improved immediately. Before working with NoName, the Danish brand had a defect rate of 15%, which meant 1,500 of the 10,000 garments produced each season were either unusable or required extensive rework. This was costing them time and money.
After NoName took over the production process, the defect rate dropped to less than 1%, with fewer than 100 defective garments per season. This massive reduction in defects helped cut down on wasted materials and labor, which directly reduced the overall production costs.
NoName follows the principles of the MSME India ZED Certification, a government initiative aimed at transforming Micro, Small, and Medium Enterprises (MSMEs) into globally competitive and sustainable businesses. The ZED philosophy—"Zero Defect, Zero Effect"—focuses on delivering high-quality products with no defects while minimizing environmental impact. By embracing this approach, NoName ensures their production processes are efficient, sustainable, and aligned with global standards, helping their clients achieve superior results with minimal waste.
Step 3: Cutting Costs and Improving Efficiency
By solving the fabric issue and improving the production process, NoName was able to lower the Danish brand’s production costs by 40%. With fewer defective garments and more efficient production, the brand saved around $10,000 per production run. This cost reduction was crucial for their business, as it allowed them to focus on growth, improve their product line, and remain competitive in the fashion market.
Why It Matters for Small to Mid-Sized Brands
For small to mid-sized fashion brands, having the right manufacturing partner is essential to controlling costs, ensuring quality, and meeting deadlines. This case study shows how important it is to work with a clothing manufacturer who understands the specific needs and challenges of smaller brands.
The Danish brand's experience highlights the damage that poor material sourcing and inefficient production can cause. However, with NoName’s help, they were able to regain control of their costs and improve their product quality. NoName’s expertise in finding high-quality fabrics, ensuring quality control, and streamlining production made all the difference.
For small to mid-sized fashion brands, a reliable manufacturer like NoName can be the key to solving production problems and achieving long-term growth.
Conclusion: NoName’s Impact on the Danish Fashion Brand
By partnering with NoName, the Danish fashion brand was able to turn around their production challenges and reduce costs by 40%. The results included:
A cost reduction from an additional $25,000 per production run to saving $10,000, thanks to NoName’s efficient processes.
A drop in the defect rate from 15% to less than 1%, which ensured higher product quality.
A consistent supply of high-quality fabrics that met the brand’s design needs.
The partnership between NoName and the Danish fashion brand led to a successful outcome, helping the brand improve cost efficiency and scale operations while maintaining high quality. NoName remains a trusted partner for small to mid-sized fashion brands across the UK, USA, UAE, Canada, Australia, and Europe, providing tailored, cost-effective solutions for growth and success.
Need a reliable manufacturing partner? Contact NoName today to help your brand thrive.
WhatsApp: +91-9717 508 508
Email: hello@nonameglobal.com
Website: www.nonameglobal.com
Online meeting: https://calendly.com/nonameglobal/meet
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