Eliminate the need to spend valuable resources on recruiting, training, coaching and supervising.
Impactiva’s Footwear Quality Assurance Program ensures that your clients are receiving the high quality products that made you their choice.
How it works
Impactiva will meet with your design and merchandising team to understand their concerns with respect to the key points of the esthetic look, fit and functionality of each style to be produced in the season. This information is then directly passed to the operators on the factory floor.
As materials begin to arrive at the factory, we will perform an in-depth quality control check. Our technicians armed with leading-edge material QC processes, ensure that the quality, look and feel meet your specifications.
Our technicians, who are permanently stationed at your factories all the time your shoes are in production, perform quality assurance from cutting through stitching all the way to final packing. They will assist factory supervisors and operators to produce Right from the start TM so as to avoid deviations, waste or defects in your shoes. This will help them to reduce process time, increase labor productivity and avoid material and product waste.
Lastly, before your shoes are shipped, our technicians perform a best-in-industry final shipment quality control to ensure that your product will exceed your expectations including verification of all packaging and labeling.
Our Service Commitment: quality related factory claim rates will drop to less than 0.4%.
“This valuable service allowed us to significantly reduce our production lead times and improve the overall quality of our finished product, eliminating customer claims and chargebacks due to defective shoes”.
Reduce your Cost of Poor Quality (COPQ) by more than 90% improving your company and brand equity! Impactiva can help you to immediately begin to achieve the below listed savings.
Factory Claims: reduce quality related claims to your factories to less than 0.4% of the pairs of shoes shipped.
Factory Costs: materials and component discards, finished product rework, finished product discards; we help to reduce factories’ waste/errors by more than 3% of the FOB cost.
Your QC Team Costs: eliminate the need of spending valuable resources on recruiting, training, coaching and supervising your own QC Team. Have the option of fast deployment trustworthy QA-QC professionals when you discover suppliers in lower cost regions or countries. Eliminate the stress and strains of disruptions from the departure of key members of your Quality Assurance / Quality Control team.
Freight Costs: air freight (caused by last minute rejections at the factory or even worse, urgent replacement of defective product that has arrived at your client) and inland freight (due to defective product returns by your clients).
Rework: avoid the pain of having to pay $3-$10 to the “shoe doctor” for the repair of defective shoes.
Client Chargebacks: late delivery and defective product chargebacks.
Gross margin loss: order cancellations (due to product returns/permanent rejection), clients putting you on probation, clients permanently stopping to buy from you.
Chargeback Administrative Handling Costs: eliminate the need to have expensive headquarter staff dedicating their valuable time to negotiate claims and chargebacks with factories and clients.
Variable vs. Fixed: turn your QA/QC costs from a fixed to a variable expense allowing you to reduce headcount and the stress of meeting monthly higher operating expense payments.
Loss of Brand Equity: avoid losing your Company’s hard earned corporate and brand image and an increase in client dissatisfaction due to repeated product quality problems.
Product Quality: improve the average outgoing quality level of your product’s esthetic look, fit and functionality using this improvement as a competitive sales advantage.
Lead-time Deterioration: avoid finding out the day of the shipment that materials have not even arrived. Improve your lead-time in days by eliminating painful delays produced by last minute rework or product rejection on shipment due date.
Organizational Tranquility: reduce the arguments – discussions – disruptions – noise level between you and your agents or factories. Diminish the stress of being “forced” to accept/approve a defective product at the very last minute. Reduce the time wasted by senior leadership on quality and production related issues (angry client calls demanding 5, 6 and 7 digit store permanent returns, organizing express shipments, ugly claims discussions with factory owners who have significant cultural differences and are across many time zones).
More Knowledge: increase the technical knowledge of your staff with respect to materials, constructions and shoe manufacturing by interacting with Impactiva’s technicians. Have your factories learn industrial engineering techniques which help them to improve their internal discipline, accountability, reliability and costs by interacting with Impactiva.
TEAM AT YOUR SERVICE
With the objective of providing a leading-edge service to your requirements and needs, Impactiva will deploy the following Team to manage your customized Footwear Quality Assurance Program:
- Footwear Quality Technicians: permanently stationed at your footwear factories
- Tech Leaders: coach, mentor and support up to eight technicians
- Footwear Production Leader: responsible for Tech Leaders
- Technical Client Care (TCC) Coordinators: responsible for defining all specifications for each style before each season
- TCC Brand Leader: your principal contact point
- Business Unit Leader: responsible for all the Team Members in the Business Unit
- Internal Footwear Quality Assurance Team: recertifies the Technicians every six months ensuring a continued compliance with Impactiva’s footwear quality assurance processes and procedures
- R&D Engineering Team: recommends improvements to existing footwear quality processes and procedures
DEFINITION OF STANDARDS
This process is one of the pillars of Impactiva’s leading-edge footwear quality assurance system. We work with you to help you define the rules of the game of your Footwear QA Program so that all parties in your footwear supply chain know how to operate. These rules of the game are converted into a ten page document called your Process and Procedure Book.
Before each season begins, Impactiva will work with your development team to understand the key concerns with respect to each style to be produced. These are turned into a “Know Your Style” spec sheet which along with material swatches and client approved confirmation and fit samples comprise the standards for each style.
Your organization will also receive ideas on how to improve processes that will help you optimize your supply chain: supplier terms of engagement, general labeling and packaging instructions, physical properties and restricted substances testing protocols.
We also can assist you to control the quality within your factories of the many steps in your development and commercialization processes including QC on your salesman, confirmation and fit samples. This reduces the lead-times of the processes by producing samples Right from the start TM.
IMPACTIVA AT THE FACTORY
We perform a reduced strength 0.65% AQL inspection on all the materials using a comprehensive series of “manual tests” that mimic laboratory tests (using Impactiva’s leading-edge material’s inspection methodology). We designate an “Approved Materials” area in each factory’s material warehouse, in order to keep the approved materials ready for use in production separate from those pending quality control. We keep samples of all approved materials and store them for future traceability and root cause analysis.
One of the keys to success of Impactiva’s Footwear QA Program is to have your factories perform a pre-production trial of a limited number of pairs on bulk-production machinery (i.e. not with sample room equipment) with the objective of detecting all manufacturing issues that can arise thus giving the factory time to correct them before thousands of pairs are produced. The average size of a purchase order in our industry has shrunk considerably during the last five to ten years to the point that most are produced in less than two days. Therefore, if issues are not solved Right from the start TM via a pre-production trial, a considerable percentage of most orders will end up requiring expensive and imperfect rework.
In order to achieve “Impactiva Quality” we teach the factory to consistently apply simple procedures at 43 key process points which bring accountability and discipline to operators throughout the entire manufacturing process. We hold a meeting before production begins on any new style with key factory operators, at Impactiva we call them artisans, to explain to them the key points of the esthetic look and fit that we downloaded from your design team. This way we psychologically motivate them to produce a great product and bring the concerns and requirements of your design team for each and every style straight to the shop floor.
Additionally, we hold daily Quality Circle meetings with the factory’s production and quality control supervisors to reiterate the issues found during the previous day and reconfirm the agreed upon corrective actions. In these meetings, we also take the time to educate the factory’s middle management on how to effectively “communicate and teach” their operators. Our objective is to get all artisans involved in helping to give ideas on how to produce shoes that meet your standards and specifications.
We help to train the factory’s QC Team to define and identify defects so that faulty shoes are returned for rework at an earlier stage in production with an ever increasing percentage of accuracy. We implement basic industrial engineering techniques in order to measure and post defect rates on an hourly basis with the aim of sensitizing the entire factory team to focus on immediate problem resolution.
Final Shipment Quality Control
We perform a tightened strength AQL Final Shipment Inspection using Impactiva’s leading-edge three part methodology. Critical tests, important tests, and optical-feel inspections are performed daily on all completed footwear orders to ensure that what is shipped fulfills your quality standards. We teach your factories how to perform a professional final QC and ask them to give us their report prior to our inspection thus making them accountable and liable. Rejected lots are reworked 100% by the supplier for identified defects.
On Time Delivery Monitoring
We assist you to manage your on time delivery of footwear orders by emitting accurate / reliable status updates every Monday with alarms for late orders. Detailed follow up of the status of particular orders can also be provided thus keeping you and your factories continuously informed of purchase orders that have very time critical ship dates.
OUR CONTRIBUTION TO CONTINUOUS IMPROVEMENT
Impactiva’s work does not end when your footwear orders are shipped. We create and maintain a culture of continuous improvement and learning throughout your entire supply chain. If any quality problems / issues arise when the shoes arrive at their destination, we work hard to obtain all the necessary information which allows us to perform a detailed and complete investigation until root causes are determined. We then immediately communicate our findings to you, your footwear supply chain partners and the entire Impactiva Team at your service and implement any changes required to processes and procedures to prevent reoccurrences.
WHY IS IMPACTIVA DIFFERENT?
DEPENDABLE QUALITY ASSURANCE
Our highly trained technicians will work side-by-side with your factory or tannery employees. Their coaching will bring reliability, efficiency and corruption-free discipline to the factory floor, protecting your brand while reducing factory waste and errors. Our technicians eliminate the need for you to spend valuable resources on replacing and training in-house inspectors.
DETAILED UNDERSTANDING OF YOUR NEEDS AND PRODUCTS
We’ll work with you on the product specifications, and then ensure this understanding is conveyed directly to operators on the factory floor. We’ll also use this knowledge to perform mandatory tests, averting costly reworks and delivery delays by detecting defects or deviations early. The result: better quality with fewer claims and chargebacks.
PROVEN, COST-SAVING PROCESSES
Our proprietary quality assurance processes will ensure proper execution at every step.