This post originally appeared on Darn It!.

The apparel industry’s supply chain crisscrosses the globe. In concept, that’s pretty exciting. In reality, it’s fraught with complications. Your supply chain can be interrupted due to all kinds of issues – some can be quite surprising!

Darn It! - first quality services

Often, quality issues in apparel supply chains stem from a few key factors:

  • As retailers pressure offshore manufacturers to meet tight timeframes, an overwhelmed factory may subcontract work. This is a prime opportunity for a breakdown in communication, resulting in garments that don’t meet specifications.
  • When a retailer begins working with a new supplier, it can take time before the factory fully understands the retailer’s quality expectations.
  • If offshore manufacturers seek to increase profit margins, they may substitute inferior fabric or trim.

As a third-party apparel refurbisher, Darn It! often receives frantic calls from apparel manufacturers, distributors, and retailers in the midst of a supply chain crisis. They have received a problematic shipment and need help getting first-quality garments on the shelves and online.

Here’s a sampling of situations that have interrupted our customers’ supply chain:

  1. Cartons of clothing had soaked in salt water – Due to a storm at port, a retailer’s shipping container with 20,000 pairs of pants had been submerged in salt water. (This is not your typical supply chain challenge!) We conducted an ozone shock treatment to remove mold and mildew, then pressed, re-ticketed, and repackaged the pants – all in time for the company’s big promotion.
  2. Correcting 56,000 mislabeled t-shirts – A retailer’s entire shipment of t-shirts arrived from the overseas manufacturer with the wrong size screen-printed on the shirts. After completing an inspection to determine correct sizes, we used a cover-up heat transfer label to overlay the correct size.
  3. 43,000 stuck zippers put $2 million in sales at risk – Beyond broken buttons, apparel often requires a variety of sewing repairs. In one case, we repaired the zippers on 43,000 sweatshirts (the zippers had the wrong slider). In another case, we replaced the red drawcord on 8,000 pajama bottoms (the dye was bleeding and staining the pajamas). In another example, the retailer’s durability test uncovered an issue with 5,000 men’s sleeveless shirts – the armholes needed to be repaired and properly reinforced. In yet another example, we repaired 16,000 lady’s wool pants with inseams that were randomly too long or too short; clearly, the garment measurements didn’t match the original factory specifications.

Having an experienced third-party refurbisher is an important link in your apparel supply chain.

Unfortunately, apparel refurbishment services are an inevitable reality of today’s globally extended apparel supply chain. As a US-based refurbisher, Darn It! can help to minimize fall-out rate, avoid consumer returns, and return garments to first-quality condition. You can rely on Darn It! to quickly get products into your customers’ hands.

Learn more about our Apparel Refurbishment services