FROM SAMPLE TO BULK PRODUCTION
A five-stage sampling and production process designed to help buyers make confident decisions at every approval gate, minimise costly rework, and protect on-time delivery. Each stage requires written approval before proceeding.
The five approval gates
Structured milestone stages governing sample progression from initial dev concept to bulk manufacturing clearance.
Top of Production (TOP) Sampling & Approval
As per buyer’s request, we will proceed with TOP (Top of Production) samples for their order. Samples will be shared for review and approval prior to bulk production.
Critical checkpoint per stage
Essential verification tasks required at each milestone gate before advancing to the next stage.
Development sample
Confirm silhouette, block, and construction methods against the tech pack and design sketch.
Proto sample
Measure all critical points against the GMS tolerance; conduct wash test for shrinkage and fastness.
SMS
Verify approved print/colourway, packaging components, and care label content.
PP sample
Confirm bulk fabric shade against dye lot, SPI, seam strength, and the agreed AQL standard.
Bulk production
Inline QC every 30-50 minutes; align final inspection booking with the freight cut-off.
Critical path analysis
The five gates above are not independent, a delay or failure at any single gate compresses every stage that follows, with no buffer once bulk starts. The bottlenecks most likely to break the timeline, and how to keep each one from cascading:
Raw material lead-time overrun
Late fabric/trim delivery pushes back cutting and compresses every downstream stage, lock fabric booking at Proto approval against a hard cutting date.
Multi-lot dye / shade variation
Mixed dye lots create shade banding once cut, match lot numbers to cutting bundles before cutting starts, not after.
Shared-line capacity bump
Factories can silently reprioritize your line for another buyer, secure written, named-date line-booking confirmation.
Mid-run quality drift
Defect rates creeping upward mid-run often go unflagged until final inspection, inline QC must trigger a hard stop, not just a log entry.
Subcontracted process delay
Outsourced embroidery/printing/washing is the top cause of missed ship dates, confirm subcontractor capacity in writing with a buffer day.
Post-inspection logistics slippage
Trucking, customs, or port congestion can eat the remaining buffer, book inspection 48-72 hrs ahead of the freight cut-off, not the sail date.
Force majeure / labour disruption
Power outages or strikes can halt a line with no contractual recovery plan, name a contingency line or backup factory in advance.
Note: Standards and certifications referenced are for general reference only, reflect common industry practice, and are subject to revision by their governing bodies. Buyer-specific requirements take precedence over the general standards described herein. Each approval must be documented in writing before the next stage commences. For questions about the sampling process, contact your sourcing manager.