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shoe quality control

Auto-vanishing pens risk – Case #648

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: the factory was using auto-vanishing pens for outsole marking. There are chances that the pen markings can reappear in cold weather.

shoe quality control

shoe quality control

Impactiva solution: we got the factory to do the sole marking with needle impressions instead of auto-vanishing pens.

shoe quality control

case 648 pic 4 impactiva footwear qa

shoe quality control

Stay tuned for more Impactiva technical solutions to every day production problems.

Impactiva Apparel Quality Control

Fast fashion calls for increasingly short lead-times

From what we read lately in fashion specialized media we get the impression that “fast” is never fast enough! All studies show that consumers want to instantly wear what they see and like. Brands and retailers work to shorten their conception-to-consumer lead-times in every possible way.

Today we want to address one of those possible ways: optimizing the link of the manufacturing supply chain that connects your Tier-2 with your Tier-1 suppliers, specifically the mills that supply fabric to your apparel factories.

A substantial part of the apparel found defective at final QC inspection is attributable to out-of-spec fabrics. Garments that get rejected at some point in production or when they are ready to be shipped, due to fabric stains, holes, knots, etc. If the mills fail to mark defects properly, the apparel factory can inadvertently cut the fabric into apparel. We know the consequences: reworks, rejections, replacements… in a word: delays… And of course: waste.

Inspecting fabric at the mill to ensure correct color, hand-feel and marking of defects can save the brand and its factories up to 20% of the fabric cost. And a lot of time.

Processes and procedures in place to prevent defects as early as possible.

These are some pictures of unmarked defects found in different clients and fabrics inspections, that can help illustrate this blog. Some are extremely noticeable and one can expect they won’t be cut into apparel, but it is best to mark all defects.

 

Stains

Fabric defect - stain 6Fabric defect - stain 1Fabric defect - stain 2  Fabric defect - stain 4  Fabric defect - stain 3Fabric defect - stain 7

 

Holes

Fabric defect - hole 1 Fabric defect - hole 2 Fabric defect - hole 3

 

Broken yarns

Fabric defect - broken yarn 1 Fabric defect - broken yarn 2

 

Foreign yarns

Impactiva Apparel Quality Control  Fabric defect - foreign yarn 3Fabric defect - foreign yarn 2

 

Pulled yarns

Impactiva Apparel Quality Control

 

Knots

Impactiva Apparel Quality Control Fabric defect - knot 2 Fabric defect - knot 3

 

Fabric joints

Impactiva Apparel Quality Control

Front

Impactiva Apparel Quality Control

Back

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Marking operation – Case #557

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: the factory was using a black cover on the marking table, what diminished the markers’ vision since they were cutting black components. This could lead to incorrect marking.

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Impactiva solution: we got the factory to use a white cover on the marking table, so that the artisans can have better vision and mark the components without errors.

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Stay tuned for more Impactiva technical solutions to every day production problems.

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Uneven eyelets distance – Case #552

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: eyelets punch distance is uneven measuring from the quarter top line edge.

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Impactiva solution: we got the factory to fix a jig on the punching machine to maintain the distance even.

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Stay tuned for more Impactiva technical solutions to every day production problems.

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Heel attachment – Case #539

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: improper heel attachment resulting in a crooked heel alignment.

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Impactiva solution: we got the factory to make a cover pattern and do a marking on the last bottom profile and on the heel part of the sole in order to match mark to mark while sole spotting for perfect heel alignment and attachment.

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case 539 pic 4 impactiva footwear qa case 539 pic 5 impactiva footwear qa

Stay tuned for more Impactiva technical solutions to every day production problems.

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Sole placement – Case #497

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: the factory was using the sole for marking its placement on the upper, but the marking was not consistent due to poor handling of the sole.

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Impactiva solution: we got the factory to make a vacuum pattern with notches on the sides, toe and heel, which is more convenient for the artisan to align on the lasted upper in the correct position in order to mark the sole placement consistently.

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Stay tuned for more Impactiva technical solutions to every day production problems.

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Thong height – Case #492

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: thong height marking was missing on the finished uppers, what might cause unevenness in the assembly.

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Impactiva solution: we got the factory to prepare a paper pattern and got it fixed at artisan’s table to mark the thong height before lasting.

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Stay tuned for more Impactiva technical solutions to every day production problems.

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Strap position – Case #488

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: inconsistent instep strap position.

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Impactiva solution: we got the factory to mark the straps position on the insoles, and follow this marking when attaching the straps.

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Stay tuned for more Impactiva technical solutions to every day production problems.

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Uneven placement of socks – Case #468

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: uneven placement of socks on the insoles.

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Impactiva solution: we got the factory to mark the insoles and to follow the marking when attaching the socks.

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Stay tuned for more Impactiva technical solutions to every day production problems.

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Pen marks – Case #458

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: improper cleaning of silver pen markings at socks edges.

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Impactiva solution: we got the factory to increase the sock marking pattern length 2mm from the toe so that marking will be hidden under the socks.

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Stay tuned for more Impactiva technical solutions to every day production problems.