A streetwear label scaling past 5,000 units/season was seeing a defect rate over 4% on delivered goods, mostly print misregistration caught only after goods landed in the US.
We added 100% inspection at the factory before goods left, checking print registration and stitch quality against the approved sample on every unit, not a sample pull.
Defect rate on delivered goods dropped to 0.4% across the next three production runs, with issues caught and reworked before shipping instead of after.