6-Stage Quality Control for OEM/ODM Sock Production
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Quality is managed throughout production rather than added only at final inspection. Our six-stage process is designed to identify material, construction, sizing, finishing and packing issues before shipment.
Stage 1: Yarn Inspection
Yarn & Raw Material Check
Before knitting, incoming yarn and required material documents are reviewed against the order specification. Composition, color and testing requirements are confirmed according to the buyer's product and target market.
Stage 2: In-Line Knitting Inspection
During Knitting
During knitting, operators and quality staff check construction, pattern accuracy, size consistency and visible defects. Inspection frequency and acceptance criteria are defined by the production and quality plan.
Stage 3: Post-Linking Inspection
After Toe Linking
The linking stage is checked for seam thickness, skipped stitches, alignment and visible workmanship issues. The inspection method and sampling level are aligned with the approved specification.
Stage 4: Boarding & Shape Inspection
Heat Setting & Shaping
After boarding (heat-setting on metal forms), we check each sock for correct size, shape, and surface finish. Socks that are stretched, wrinkled, or don't match the foot form are pulled. This is also where we verify color consistency across the production batch.
Stage 5: Final Inspection
Buyer-Specific Sampling Plan
Finished goods are checked for dimensions, weight, color, labeling and packaging. The applicable sampling plan, acceptance limits and reinspection route are confirmed with the buyer for each order.
Stage 6: Pre-Shipment Inspection
Before Container Loading
Before goods leave the factory, we perform a final check: correct quantities, proper packaging, carton markings, and shipping documentation. We also take photos of the container loading process and share them with the client as proof of shipment condition.
The cost of catching a defect at Stage 1 is 1/100th the cost of discovering it at Stage 6. Early detection isn't just quality control—it's cost control.
Why 6 Stages Matter for Your Brand
For brand owners, a factory with a rigorous multi-stage QC system means:
- Fewer returns and complaints from your end customers
- Consistent quality across production runs and seasons
- Confidence in scaling — quality won't drop as volume increases
- Compliance documentation that passes retailer audits
Written specifications, an approved sample and agreed inspection criteria create a clearer basis for quality decisions throughout production.
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