Sample Answer
On a large denim program for a European retailer, we were at 40% bulk and facing a 12% rejection rate due to shade variation and back rise twist. Shipment risk was about $1.2M. I pulled together merchandising, production planning, QA, the laundry, and factory technicians into a daily 30‑minute war-room for one week. First, we mapped the process and agreed on one shared target: get rejections under 2% without missing the ex‑factory date. I had QA bring hard data, merch share buyer expectations, and the factory walk us through real constraints. From there, we standardized wash recipes, re‑set pattern/block for the back rise, and introduced a 100% inline check at key operations for 3 days. Within 10 days, rejection fell from 12% to 1.5%, and we shipped on time with no chargebacks. The factory later adopted that war‑room model for two other key accounts with similar success.
Keywords
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