Many people wonder why their products ship out with defects. How does this happen? Why does this happen? And what can you do to prevent it?
How do defects happen?
Simply put, something was overlooked. For example you send a drawing of a base layer shirt to a factory abroad and tell them to make it. You gave them sizing and fabric information but neglected to give them construction information. Now the shirt looks great but all the stitches are breaking and unraveling. This could be prevented with specifying to the factory what type of stitch & stitch count they needed to use for each area of the garment.
Why do defects happen?
We assume too much. We assume the factory knows what we have in our head as the end result and we assume the factory understands our level of quality standards. We assume the factory understands sizing, color, etc… We assume the fabric color won’t bleed and the buttons won’t fall off. If you think of constructing a garment much like building a structure this will help. For instance, a building needs load bearing walls, a foundation and many more things that must meet code to ensure the building holds up. The codes are specified and inspected by a professional each step of the way. A good fitting pattern, appropriate trims, and correct construction methods are required to ensure the integrity of the garment much like building a structure.
How to prevent future defects?
1st providing or proofing the pattern for the garment. The shapes and contours of each size must precisely match what is needed for the garment to fit correctly for its final function.
2nd specifying ALL details required to assemble the pattern or cut pieces in the form of a tech pack or spec sheet. Listing the types of machinery needed to join each component and how is essential to the garment holding up.
3rd Sample, check, then sample and check some more. Not one thing should go into production without being approved of first. This includes labels, label placement, buttons, button placement, trim breakage tests, neck tape, color , packaging and SO much more!
When ordering mass quantities of anything there is bound to be some fallout. The steps can reduce that fallout to 1% or less of your total inventory. This is a massive amount of savings in the short-term and long term for your brand integrity.
Clothier Design Source is very passionate about this issue and is here to help in all ways described above. Please contact us if you need help in any of these areas. www.clothierdesignsource.com