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What is your clients' goal by moving to an inventory model?
There are definitely savings buying your own shirts and stocking but you need to calculate the costs of unsold inventory, running out of stock, stocking multiple sizes, getting stuck with a design that just won't sell.... so many ways to hemorrhage cash when stocking your own inventory -- not even counting the cost for a 3rd party distributor
unless he's been in the biz and knows his sales well, it's a much bigger risk since you're putting all the money up front.