Case Study — Resistance Band Program for a Major US Discount Retailer

OEM Partnership · Mass Market · Better Sports

This case study describes how Better Sports partnered with a top-three US discount retailer to supply resistance bands at scale, replacing an incumbent vendor and ultimately expanding the relationship across multiple product categories.

The Challenge

The retailer had been sourcing resistance bands from a supplier in Southeast Asia for three years. While pricing was competitive, quality consistency had deteriorated: batch-to-batch variation in elasticity, occasional seam failures, and delayed deliveries during peak season. The buyer’s QA team logged three major defects per quarter, triggering costly chargebacks and customer returns.

The Selection Process

The retailer issued an RFQ to five suppliers in China and Vietnam. Better Sports was shortlisted based on:

• Existing BSCI and ISO 9001 certifications.
• Ability to replicate the existing SKU set without redesign.
• Capacity commitment for monthly FCL shipments.
• Quoted price within target range with transparent cost breakdown.

Onboarding & Ramp-Up

After a two-day factory audit, the buyer approved Better Sports as a secondary supplier. Phase one involved five SKUs with a trial order of 50,000 units. Key onboarding steps:

1. Sample approval: First samples submitted in 8 days; second samples approved after color-matching adjustments.
2. Tooling review: Existing moulds inspected and calibrated to match the retailer’s tension specifications.
3. Packaging setup: UPC labels, hangtags, and retail polybags produced to the retailer’s style guide.
4. Pre-shipment inspection: SGS conducted FRI at AQL 2.5; lot passed on first attempt.

Results After 18 Months

• Quality: Zero defect-related complaints across 900,000+ units shipped.
• Cost: Unit cost reduced by 12% through material-yield optimization and consolidated packaging.
• Delivery: On-time delivery rate improved from 78% (previous supplier) to 97%.
• Growth: Program expanded to three additional product lines: yoga mats, foam rollers, and jump ropes.

Key Success Factors

1. Documented process control: Every production lot is traceable to raw-material batch and operator station.
2. Proactive communication: Weekly production reports and early warnings for any potential delays.
3. Continuous improvement: Quarterly business reviews identify cost-saving and quality-enhancement opportunities.