Quality Control Workflow in Footwear Industry

Footwear is a big part of Fashion in our daily life. Footwear industries make Sneakers, Loafers, Boots, Keds, and many other functional shoes and boots. 6 Basic Quality control points in the footwear industry: those are Toe Spring, Rocking, Outsole, Clean, Shine, and Straight. A digital screen that displays all the QC and notice-related data on the working floor. This creates a better target-driven workforce and mindset among all in the footwear industry to get a better quality result. I present details on the Quality Control Workflow in the Footwear Industry.

Workflow of Quality Control Team in the Footwear Industry

1. We can find quality control in different places of starting from the material in-house to the product delivery end.
2. When a material arrives against a confirmed shop order, the IQC (Incoming Quality Control) team checks every material against a PD signed swatch. There is a predetermined SOP for the IQC for material checking, and after it is done, they generate a report. All problems are documented, and a checklist is formed to keep track.
3. After the material is stored in the warehouse, requisitions are made to bring the material to the cutting section. Here we have in-line QC who will address rework or correction via tannery if needed, due to variations in cut components. Before rejection, they consider cases of repair, rework, and recycling.
4. Before bulk cutting or sewing, 1 pair is cut or 1 pair’s whole upper is attached and shown to QC. QC compares the prepared sample with the tech sheet, show board, and customer sample. Adds a note of improvement or perfection, and then bulk production begins.
5. In sewing, during bulk production, there is a mid-line QC. They are between the upper to lining transition. If they pass upper, then lining stitching and attaching begin. They also fill up a form and add corrections or defects in it. Then there is a final QC. They check the complete upper and create a report before dispatch.
6. When these upper reach the lasting floor along with beforehand provided accessories checked by QC, a random QC conducts AQL (Acceptable Quality Limits).
7. If the upper passes, they go for lasting, and otherwise, they are sent back to the sewing department. Random QC also generates reports on a daily and monthly basis.
8. In the lasting line, there is in-line QC before roughening operation as well as a 1 pair trial check QC at the beginning before bulk production. They check, but they don’t generate the report. The final table QC checks and gives the report.
9. Next, the boxed shoes move to the packaging warehouse in trolleys, where they undergo another random QC. If they pass, they undergo an AQL check before customer inspection.
10. If it fails, then rework is done in re-control lines in a separate place and passed down for another inspection.
11. Fungus has to feed on oil, protein. Black leather shoes for cold countries are mostly oil tanned or oil coated to make them moisture repellent. But these oils drive out fungus, making the leather empty. To control this, the shoes are passed through a 243 nm wavelength Ultraviolet ray that kills these fungi. In addition, HDLP filament is added inside to reduce moisture and decrease the growth of fungus.

Conclusion

Quality is the first thing we consider when buying any footwear items. These points mentioned here are equally important for maintaining proper Workflow of the Quality Control Team in the Footwear Industry.