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Case studies · Consumer goods

Toys to toasters,
triage to turnaround.

From function testing to component replacement, mold saves to kitting surges. This is how QCI returns consumer-goods shipments to first quality, and keeps programs on the calendar.

01Consumer goods repair case studies

Problem → first quality.

Furniture inspection & repair

Barstools and cocktail tables, damaged in transit.

Damaged→97% saved

The problem

A leading importer of furniture for the convention and events industry received barstools and high-top tables damaged by load shifts and moisture: broken and scratched legs, scuffs, rust.

The fix

QCI triaged the load: unloaded, inspected, and sorted to client-defined criteria, then replaced components, sanded and touched up paint, cleaned surface rust, and repackaged to standard. Over 97% of the shipment returned to first quality.

Eyewear rework

Temple tips loose on a new style of metal frames.

Loose→secured

The problem

An importer’s audit found that on one problematic style, the temple tips weren’t secured to the metal arms of the eyeglass frames.

The fix

QCI accessed each core wire, applied a thin adhesive layer, reseated the temple tips, inspected every unit after drying, and repackaged in full compliance with the client’s specifications.

Mold remediation

A furniture shipment, moldy on arrival.

Moldy→exceeded spec

The problem

A large retailer’s inbound inspection found an entire shipment of furniture affected by mold.

The fix

QCI received the entire shipment, cleaned and sanitized it with our proven remediation process, and returned all the furniture in new packaging, meeting and exceeding expectations.

Mold remediation

Nearly a million plush toys, weeks before the season.

~1M units→season saved

The problem

Nearly a million units of an importer’s seasonal plush toys failed AQL inspection for mold. The product was already expected on store shelves.

The fix

QCI unpacked, inspected, cleaned, and sanitized the entire order, replaced packaging, and our logistics team routed pick orders directly to key accounts, saving the shopping season.

Mold remediation

Three-piece travel bag sets with mold.

Days→back in distribution

The problem

An accessory importer discovered mold on inspection of their three-piece nylon travel-bag sets.

The fix

Two thousand sets of three bags each were cleaned and sanitized via our exclusive process and back in distribution within days. All units first quality, no lost sales.

Custom rework

Curio cabinets with broken mirrors and falling felt.

Broken→rebuilt

The problem

A mail-order company’s curio cabinets arrived with broken mirror frames and interior felt falling off, so every unit had to be unpacked and inspected.

The fix

QCI inspected and sorted, then re-glued every felt interior, repaired the broken mirror frames, and cleaned and repackaged all units.

Inspect & repair

Umbrella handles that wouldn’t stay on.

12,000 units→all shipped

The problem

A random audit showed handles not adhering to poles per spec. Rejecting the shipment and waiting for a replacement would have cost the importer the season.

The fix

QCI inspected and pull-tested over 12,000 units, set aside passing product, and re-glued the defective handles with the appropriate adhesives. All 12,000 units were cleared for retail.

Custom rework

Luggage pull handles that generated complaints.

Complaints→upgraded

The problem

Executives at a prominent luggage importer decided to replace the pull handles on a new hard-case style after consumer complaints.

The fix

QCI carefully removed and replaced the handle mechanisms, renovating the line with upgraded hardware worthy of the brand’s die-hard reputation.

Contract packing & kitting

Conference welcome bags, from a dozen vendors.

Bulk→floor-ready

The problem

An event-management company needed kitting and fulfillment of attendee welcome bags for a national trade association’s conference.

The fix

QCI received and warehoused bulk shipments of promotional products and brochures from multiple vendors, kitted everything into welcome bags, and delivered to the exhibition floor on schedule.

Packaging & kitting

A 30,000-piece brochure job on an impossible deadline.

Overloaded→on deadline

The problem

A local printer won a 30,000-piece promotional brochure project needing special folds and precise insert order in time for a Las Vegas trade show, on top of existing deadlines.

The fix

QCI absorbed the surge: received the materials, executed the special folds and ordered inserts to spec, and completed the project within the deadline for a successful show.

Inspect & sort

500,000 binders with broken rings.

Rejected→recovered

The problem

An office-supplies importer’s AQL inspection found broken plastic rings across a shipment of 500,000 3-ring binders. The shipment was rejected.

The fix

QCI accepted the shipment, sorted first quality from defects, destroyed the defective units, and assisted the importer with the duty-drawback process.

Component replacement

Plush ballerina bears shedding glitter.

Shedding→compliant

The problem

An AQL inspection found the glitter on toy bears’ dresses improperly glued. Just removing a bear from its box shed glitter everywhere.

The fix

QCI worked with the vendor to source replacement dresses, removed the defective ones, cleaned every bear of residual glitter, and dressed the order to CPSC-compliant standard.

Hardware replacement

Case goods with a defective hardware finish.

Defective→first quality

The problem

A large furniture retailer received dressers, nightstands, chests, and headboards whose hardware had a defective finish.

The fix

QCI worked directly with the vendor to source replacements, swapped the hardware at speed, and returned the entire furniture shipment to first quality.

Component replacement

Faucets already in stores, failing in the field.

In the field→sellable

The problem

A major kitchen-and-bath manufacturer’s faucets were failing in the field. Components had to be replaced on every unit, many already in stores and DCs across the country.

The fix

QCI received replacement parts from the overseas manufacturer, coordinated inbound freight with the retailer’s logistics team across both facilities, opened every package, and swapped the components, returning the units to sellable, first-quality product.

Function testing

15,000 space heaters with loose wiring.

15,000 units→97% saved

The problem

Rough transit handling left a big-box retailer’s electric space heaters with detaching wires and damaged wooden cabinets.

The fix

QCI unpacked and function-tested all 15,000 units, soldered and tightened every wire connection, and retouched the cabinets. That returned 97% of the shipment to first-quality condition.

Function testing

Novelty humidifiers with a 25% failure rate.

25% failing→sorted & certified

The problem

End users were returning a big-box retailer’s novelty humidifiers; testing showed over 25% of units not functioning properly.

The fix

QCI received all remaining stock from the DC, function-tested every unit, sorted good from bad, and disposed of the defective units through our product-destruction services.

Product alterations

7,000 backpacks with straps that couldn’t take the load.

Failing→re-engineered

The problem

A backpack manufacturer had strap failures in the field from poor attachment, with the product already in U.S. warehouses.

The fix

QCI reinforced the straps and webbing on all 7,000 backpacks, and worked with the designers and manufacturers in Asia on a fix that became a permanent manufacturing change. First quality, no lost sales.

03More recoveries

Keep reading.

Footwear

Footwear repair & rework case studies

Mold on 60,000+ pairs, loose straps on 80,000 sandals: the toughest, largest-scale footwear recoveries.

Read the stories→ Apparel

Apparel case studies

Crocking, color bleed, garlic-scented sleepwear, and a million lead-tainted buttons, all returned to first quality.

Read the stories→ Accessories

Accessories case studies

Handbags, gloves, backpacks, belts. Millions of accessories brought back to first-quality condition.

Read the stories→ Consumer goods

Consumer goods repair case studies

Function testing, component swaps, furniture triage, and near-million-unit mold saves.

Read the stories→

Free project analysis

Have a shipment problem? Let’s solve it!

Supply chain problems don’t wait, and neither do we. Tell us what happened and we’ll take it from there: our team will evaluate the defect, determine the most effective solution, and develop a customized recovery plan with transparent pricing and an estimated turnaround. Most sample analyses turn around within 24 to 48 hours.

Request a free project analysis Or call 1.800.340.8384