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High Rejections?
We Help Identify Root Causes and Strengthen Your QC Process

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High Rejections?
We Help Identify Root Causes and Strengthen Your QC Process

We help brands and factories connect efficiency with creativity

In the apparel manufacturing industry, one of the biggest challenges factories face is high rejection rates. Every rejected piece is not just a product lost — it’s wasted raw material, time, labor, and ultimately, profit. Frequent rejections also impact brand reputation and buyer trust.

Common Causes of High Rejections in Apparel Manufacturing
1. Inconsistent Fabric Quality

    Variations in color, shrinkage, or defects in fabric often lead to product failure.

2. Improper Stitching & Workmanship Issues

    Weak seams, skipped stitches, and loose threads are frequent rejection points.

3. Lack of Standardized Processes

    Without well-defined Standard Operating Procedures (SOPs), production quality varies from batch to batch.

4. Inadequate Training

    Operators without proper skill development make more errors, raising rejection levels.

5. Insufficient In-line Inspections

    Identifying issues only at the final stage often results in higher rejections instead of catching errors early.

The Solution: Strengthening Your Quality Control Process

Reducing rejections isn’t about checking more products—it’s about building quality into the process itself. Here’s how we help:

  • Root Cause Analysis (RCA)
    We don’t just fix surface-level issues. We analyze where the problem originates—be it raw material, methods, or manpower.
  • Process Standardization
    Developing SOPs and ensuring operators follow them consistently minimizes errors.
  • Skill Training:
    Training workers on quality standards, machine handling, and best practices reduces mistakes at the source.
  • In-line QC Systems:
    Placing inspections throughout the production line allows issues to be caught and corrected early, reducing large-scale rejections.
  • Continuous Improvement:
    We implement quality improvement tools like 5 Why Analysis, Fishbone Diagrams, and PDCA cycles to create a sustainable QC culture.

Why This Matters

When rejection rates fall, factories experience:

  • Higher efficiency and lower costs.
  • Increased buyer confidence.
  • Faster lead times and smoother deliveries.
  • A stronger reputation in the market.