What happens when a batch fails
Short answer: The factory gets a list of the faults and the batch stays where it is until an agreement is made. Then it is decided whether the goods are sorted, repaired, sold at a discount or scrapped.
The factory receives a fault list
When an inspection finds faults, it is not enough to say that something is wrong. The factory gets a concrete list with the number, location and preferably photos of each fault. The list shows whether a few pieces or the whole batch are affected, and everyone works from the same facts.
The batch stays put
Until the faults are sorted out, the batch does not leave the factory. The goods are not packed for shipping and not mixed with other deliveries. It feels like lost time, but it is the safest way to stop faulty pieces reaching customers and causing complaints that cost far more to fix later.
Sorting is the usual answer
If the fault only affects part of the batch, every garment is checked one by one. The poor ones are taken out and set aside, while the rest is packed as planned. It is slow, but it works well when the fault is random and not in the fabric or in how the whole batch was sewn.
Repairs take time
If seams have to be resewn or labels replaced across the whole batch, it takes days or weeks. Delivery slips, and the goods may miss the season. It is a trade-off between having a finished product and having it on time, made again for each batch. Take a look at the CCDK collection as well.
Some faults cannot be fixed
If the fabric is dyed wrongly or shrinks too much, neither sorting nor resewing helps, because the fault sits in the material itself. Then the whole batch has to be assessed again. See also the collections from Lindbergh and Resteröds.
Discount as an option
If the fault is small and harmless, the goods can sometimes be sold at a discount. This requires that the fault is described honestly, so the customer knows what they are buying. A visible cosmetic flaw is different from a fit problem, and that difference has to be clear before the item goes on sale.
Scrapping as a last resort
If nothing else works, the batch, or the worst pieces in it, is scrapped. It is the most expensive solution, so it is chosen only when the fault cannot be fixed and the goods cannot be sold honestly. Usually it is agreed beforehand who carries the loss, which gives the factory a reason to improve its checks.
A new check before approval
A repaired or sorted batch is inspected again before it is approved. Otherwise nobody knows whether the repair worked or whether new faults appeared. The check follows the same list as the first time, so the same points are tested and the result can be compared directly with the starting point.
What it means for you as a customer
For you as a customer, it usually means a later delivery or an item that leaves the range. Waiting is annoying, but better than receiving a faulty piece. If you still get a faulty item, write to customer service with a photo and your order number so the case can be followed up.
Frequently asked questions
Who pays for the sorting
Typically the factory, when the fault is its own. Sorting is part of delivering the agreed quality, so the cost normally sits with whoever made the fault, unless something else was agreed in the order.
Can the goods still be sold
Sometimes as seconds, if the fault is visible and harmless and the customer is told before buying. It needs a clear description and usually a lower price.
Is it checked again afterwards
Yes. A repaired batch has to pass a new inspection before approval, so it is certain that the repair worked and that no new faults appeared along the way.
You can find the full range at Bamboo-Clothing.com.
