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Quality isn't a final step. It's a continuous check at every stage — incoming fabric, print, sewing, pre-shipment. AQL 2.5 sampling. 8 dedicated QC staff. Audit-ready.
Quality control isn't one step. It's a funnel. Defects caught at fabric arrival get rejected before any labor is invested. Defects caught at print stage get re-printed — a $2 fix. Defects caught at sewing get reworked — a $3-5 fix. Defects caught only at final QC require replacement pieces — $15 plus a delayed ship.
We check at every stage, not just at the end. This is how we hit 99.2% first-pass and <0.1% final-shipment defect rate. It also means a defect caught at stage 1 doesn't drag down the whole line.
Our QC team is 8 dedicated inspectors, separate from the production team. They have authority to stop a line. They report to a QC manager who reports to the COO, not to the line supervisor. Independence matters.
Every fabric roll inspected on arrival: GSM, width, color consistency, hand-feel, defect count. We reject 3-5% of incoming lots — typically fabric that doesn't match the spec or has visible flaws.
After sublimation printing, each panel is checked for color accuracy (vs Pantone), registration, ink coverage, edge crispness. Defective panels re-printed, not reworked.
Inline QC at each sewing station checks stitch count (8-10/inch), seam alignment, tension, thread trim. Random pull-tests every 50 pieces. Defects removed before heat-pressing.
AQL 2.5 final inspection: random sample pulled per lot, full defect classification, photo report, pass/fail. Failed lots reworked or rejected before any carton is sealed.
Pantone-grade color calibration at print, light-box final check against master sample. We've matched brand colors to within ΔE < 1.5 for 200+ race teams.
Strict zero-defect shipment. We pull a 30-piece AQL sample per 1,000-piece lot, full reject if any critical defect found. POD return rate: <0.4%.
12-point measurement per garment, ±1cm tolerance. We sort by size on the packing line, not by carton. Schools receive uniform-size bundles they can distribute without re-sorting.
Pre-shipment audit on every lot, photo report + measurement report. Brand QC team can fly in for an unannounced visit — we've hosted 4 in the last 12 months.
Sample at 2 weeks, bulk at 4 weeks, but bulk must match sample within ΔE < 2. We hold the original sample for comparison until the order is shipped.
Stock in CA is from a previously QC-passed lot, but we re-inspect on pull: fold condition, poly-bag integrity, label legibility, no transit damage.
99.2% across the last 12 months. The 0.8% is split between incoming fabric reject (0.4%) and in-line defects caught before final QC (0.4%). Final-shipment defect rate is <0.1%.
Yes, anytime. We host 8-12 inspector visits per year (SGS, Bureau Veritas, brand QC teams). Inspector accommodation and access arranged free of charge.
We segregate, count, and either rework (if defect is repairable) or destroy (if not). You receive a written report with defect count, root cause, and corrective action. Replacement pieces ship in the next available batch at our cost.
ISO 9001:2015 (quality management) and OEKO-TEX Standard 100 (fabric safety). BSCI social compliance audited. Sedex SMETA 4-pillar available. Audit reports shared under NDA.
We host 8-12 inspector visits per year. Accommodation arranged, full factory access, and your team can pull a random AQL sample alongside ours.