What can go wrong in a production run
Short answer: Colour can come out wrong, fabric can shrink more than agreed, measurements can drift and seams can end up too tight. Most faults are caught in inspection, but not all, so it helps to know what goes wrong most often.
Colour can deviate
Colour deviation is one of the most common faults. Dye can take differently from batch to batch, and the light in the factory is not the light at home. So the colour is compared with an approved sample, and batches that stray too far cannot move on without an agreement.
Fabric can shrink more than agreed
Unexpected shrinkage is one of the costliest faults. A fabric that shrinks more than agreed in the wash gives garments that end up a size too small. The fault hits the whole batch at once and cannot be fixed with a new seam, because it lies in the fabric itself.
Measurements can drift
If a measurement drifts through the batch, a garment can be half a size off. This happens when templates wear down or the fabric is pulled slightly during cutting. It shows only when garments are measured against the chart. See bamboo shirts for women and compare measurements with a garment you already own.
Seams and sewing
Seams can be too tight, too loose or uneven. A tight seam pulls the fabric together and causes puckering, and a loose seam can open in use. These faults often appear when an operator changes or a machine is set wrongly, and show most at shoulders, side seams and neckline.
Labels and care instructions
A wrong size label or care instruction is easy to overlook and costly to fix afterwards. A size M with an L label can end up with a customer who gets an unpleasant surprise. So labels are checked separately, and the care instruction must suit the fabric in the garment.
Packing and marking
Faults can also arise at the very end. Garments can be packed in the wrong carton, in the wrong quantity or with the wrong barcode, so the warehouse receives goods it does not expect. See offers for women and Moodies, and remember that packing and marking are part of quality too.
Inspection catches most faults
Most faults are found in inspection, where a number of garments are taken from the batch and examined. Inspection is based on samples, so it cannot guarantee that every single garment is flawless. It does give a good picture of whether the batch as a whole meets what was agreed.
What happens to a faulty batch
A faulty batch can be corrected, sold as seconds or rejected, depending on how serious the fault is. Colour faults and shrinkage are rarely fixable. Measurement and sewing faults can sometimes be resewn. The decision is made between brand and factory and depends on what was agreed beforehand.
What you can do yourself
Follow the care label and try the garment on before you cut off the tag. If you find a fault, contact the shop and describe what is wrong. A photo of the fault helps. Not all faults can be avoided, but most can be solved if reported quickly and clearly.
Frequently asked questions
Are all faults caught?
No. Inspection is sample based, so single garments can slip through. That is why a complaint is always possible if you find a fault when you unpack the goods at home.
What happens to a faulty batch?
It is corrected, sold as seconds or rejected, depending on the fault. The decision depends on how serious the fault is and what the brand and factory agreed beforehand.
Who pays for the fault?
It depends on the agreement, but the factory is typically liable for faults it caused itself. Faults caused by the brand's own specifications may rest with the brand, so it must always be clarified.
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