Avoid lead-time delays and prevent defective PU from arriving at your factories.
Impactiva’s PU Quality Assurance Program ensures that you receive the PU you specified, without hidden defects that surface during product manufacturing.
How it works
Before the start of each season, Impactiva meets with your materials team to precisely define your PU standards. Thus, 100% of the PU orders can be inspected at your PU supplier facilities and sent directly to your factory cutting rooms without re-inspection.
When each production lot is ready for shipment, our technicians go to your supplier facilities and perform our proprietary PU inspection process, ensuring that each lot is individually evaluated. Impactiva technicians perform a sample-based AQL inspection to verify the organoleptic characteristics of each lot.
Our Service Commitment: +99% of the square feet will arrive at your factories without quality-related claims.
Improve your company and brand equity while reducing your cost of poor quality by more than 90%. For instance, Impactiva can help you to quickly achieve the following savings.
Supply Chain Optimization: remove waste and errors in your PU supply chain.
Factory Claims: reduce quality-related claims to your PU suppliers to less than 1% of the square feet shipped.
QC Team Costs: eliminate the need to spend valuable resources on recruiting, training, coaching and supervising your own QC team, as well as disruptions from the departure of key QA/QC team members. Have the option of rapidly deploying trustworthy QA/QC professionals when you discover suppliers in lower-cost regions or countries.
Freight Costs: eliminate expensive air freight shipments of replacement PU and finished products.
Factory Costs: reduce various factory costs that can affect the final product price, such as components or final products destroyed due to defective PU, overtime due to disruptions in production schedules, PU warehouse inspectors, purchasing staff time spent handling claims and B grading of final products.
Client Chargebacks: cut chargebacks due to late delivery or defective PU in the final product.
Gross Margins: decrease instances of clients cancelling orders, putting you on probation or ending the relationship.
Chargeback Administrative Handling Costs: eliminate the need for expensive headquarters staff to spend time negotiating claims and chargebacks with PU suppliers, factories and clients.
Variable vs Fixed: turn QA/QC costs from a fixed to variable expense, allowing you to reduce headcount and the stress of higher monthly operating expense payments.
Brand Equity: avoid damaging your company’s corporate and brand image and increasing client dissatisfaction due to repeated PU quality problems.
PU Quality and Competitiveness: achieve a competitive sales advantage by improving the average outgoing quality level of your final product.
Lead-time: ensure that your PU can go directly to cutting (instead of waiting for claims to be negotiated), thereby improving final product lead time.
Organizational Tranquility: reduce arguments, disruptions and tension between you and your factories and PU suppliers. Eliminatethe pressure of accepting late product shipments and being forced to approve substandard PU at the last minute. Elieviate the time spent by senior leadership on quality- and production-related issues (e.g., factory owner calls, express shipments, claims discussions with PU suppliers and/or factory owners who have cultural differences and are located across many time zones).
Knowledge: increase the technical PU knowledge of your internal and factory staff by interacting with Impactiva’s technicians.
TEAM AT YOUR SERVICE
To provide the high-quality service needed to meet your requirements and needs, Impactiva will deploy the following team members to manage your customized PU Quality Assurance Program:
- Technicians who are permanently stationed at your PU supplier factories
- Tech Leaders who coach, mentor and support up to eight technicians
- Leather Production Leader who coaches and leads all tech leaders
- Technical Client Care (TCC) Standards Coordinators who define all specifications for each season’s leather types
- TCC Factory Coordinators who help your factories resolve any PU issues that arise
- TCC Brand Leader who is your organization’s principal contact person
- Business Unit Leader who coaches, mentors and leads all team members in the business unit
- Internal Leather Quality Assurance Team that recertifies technicians every 6 months to ensure continued compliance with Impactiva’s processes and procedures
- Research and Development Engineering Team that recommends improvements to existing processes and procedures
DEFINITION OF STANDARDS
This process is one of the pillars of Impactiva’s leading-edge PU QA system. We work with you to define the rules and requirements of your PU QA Program, ensuring that all parties in your supply chain understand the details of how your Program will function. Then, we convert these details into your 10-page Process and Procedure Book.
Before each season begins, Impactiva works with your materials development team to understand key concerns regarding each PU type to be sourced. These concerns are captured in “Know Your PU” spec sheets, which, along with the PU confirmation sample, color windows and range swatches, comprise the standards for each PU type.
We hold periodic meetings with you, your PU suppliers and your factories to ensure uniformity of PU confirmation swatches and discuss the standards and tolerances for PU characteristics, colors and processing defects. We help to optimize your PU supply chain by providing ideas for improving PU purchasing contract terms, PU packing instructions, physical properties and restricted substances testing protocols. Further, we can help you to produce salesperson and confirmation samples Right from the start™, thereby reducing the lead times of time-critical PU development and commercialization processes.
IMPACTIVA AT THE SUPPLIER’S FACILITY
Development Quality Control
We perform a thorough QC at the PU supplier’s facility before the shipment of prototype, salesperson sample or confirmation sample PU, thereby reducing your development sample error rate and the total process cycle time.
Production Quality Control
We perform a series of manual tests, including color matching, thickness, tear strength, delamination, adhesion and rub-fastness, on every PU lot. Each test mimics actual laboratory tests, and if any lot fails, we ask the PU supplier to validate the results in their laboratory.
If the results are confirmed, the lot is rejected, and the PU supplier is asked to rework or remake the order. If the lot passes, our technician performs a sample-based AQL inspection for the PU characteristics, and the lot is approved or rejected. Once each lot inspection is finalized, a detailed report is produced.
On-Time Delivery Monitoring
We help you manage the delivery of your PU orders by producing accurate, reliable weekly status updates, each with alarms for late orders. We can also provide detailed follow up on the status of particular orders, thus keeping you and your factories informed of purchase orders with time-critical ship dates.
OUR CONTRIBUTION TO CONTINUOUS IMPROVEMENT
Impactiva’s work does not end when your PU orders are shipped. Instead, we create and maintain a culture of continuous improvement and learning throughout your entire supply chain. If any quality problems or issues arise when the PU arrives at the factories, we gather all necessary information and perform a detailed investigation to determine root causes. We immediately communicate our findings to you, your PU supply chain partners and the Impactiva team, then implement any process or procedure changes needed to prevent reoccurrences.