A single SKU from Thailand is a project. A twelve-SKU range across metal, plastics, textiles and packaging is a programme, and it fails on sequencing far more often than on price.
Sequence categories by risk, not by excitement
| Order | Category type | Why it goes here |
|---|---|---|
| 1 | Tooled items (moulding, die-cast) | Longest lead time, tooling gates everything |
| 2 | Fabricated and CNC items | Setup driven, needs first-article approval |
| 3 | Textiles and soft goods | Fabric and dye-lot lead times |
| 4 | Packaging and print | Must follow final dimensions and artwork |
| 5 | Accessories and fillers | Add last, cut first if the date slips |
Starting with packaging is the classic mistake. Artwork depends on final part dimensions, and part dimensions are not final until tooling is validated.
A realistic 20-week timeline
- Weeks 1–3 — specifications frozen per SKU, suppliers qualified per category.
- Weeks 4–7 — tooling cut, fabric and material sourcing started in parallel.
- Weeks 8–10 — first samples per category, pre-production sample approvals.
- Weeks 11–12 — compliance testing on approved samples, artwork locked.
- Weeks 13–17 — mass production, staged by category with a shared ex-works cut-off.
- Weeks 18–20 — inspection at each factory, consolidation, loading and sailing.
Compress this and you compress the sample gates, which is where quality is decided. For buffer planning see the lead time and buffer guide.
Share components across the range
One carton footprint, one closure, one insert material and one label format across twelve SKUs reduces tooling, raises effective volume and simplifies inspection. It is also the most effective way to bring minimums down — see the low-MOQ guide.
Gate the range with sample approvals
Use three gates per SKU: first article, pre-production sample, and golden sample retained by both sides. No SKU enters mass production without a signed golden sample; without it, disputes over "acceptable" finish have no reference point.
Costing a range honestly
Allocate tooling per SKU over first-year forecast, not over lifetime hopes. Split freight by chargeable volume rather than averaging across the container so weak SKUs are visible before reorder. The landed cost calculator handles both.
How TUSKO runs range launches
We qualify one supplier per category, hold the sample gates, arrange compliance testing, run engineer-led inspection at each factory, then consolidate into one shipment with one document set. You place orders through us and track every SKU, supplier and document in one dashboard.
FAQ
How long does a multi-category range take from spec to sailing?
Plan around 18 to 22 weeks when tooling is involved and 10 to 14 weeks when all items use existing tooling. The tooled category sets the critical path, so everything else is scheduled backwards from its validation date.
Which category should be sourced first?
The one with tooling or the longest material lead time. Packaging and print go last because artwork depends on final part dimensions and weights, which are only confirmed after tooling validation.
Can different categories share one purchase order?
Commercially yes, and it simplifies documents when you buy through one party. Technically each SKU still needs its own specification, sample approval and inspection record, since acceptance criteria differ by process.
What is the most common cause of a delayed range launch?
Late artwork approval and skipped pre-production samples. Both look like small administrative steps but they sit directly on the critical path and rework after mass production costs a full production cycle.