I’ve heard that some (maybe most) companies use the first couple hundred production pieces as a “test” run to get the workers trained and work out any bugs. These couple hundred units are then destroyed and never make it to shelves. The idea behind this is that after this test run is done all future production will be “perfect”.
Is this really done? If so do companies have to request this of their Asia factories, or do the factories do this on their own?
Are there any more efficent ways to ensure the QC of production? Meaning, makeing sure the craftsmanship (seams, stitching, logos) are just as perfect as the approval samples.
Thanks in advance.
Most experienced factories use the Sales samples runs, as the primary once over for production.
Although there are a series of tech samples or pullovers done in the process (generally at least 3-5 tech revisions), this is normally taken care of off the production line and in the sample/ development room. That way- if things need to changed, the people, tools, and machines can be modified accordingly- and quickly.
This is very typical in high tech. Small Production Runs (SPRs) are effectively a mandatory aspect of the process. Getting in bed with your manufacturer as early as possible is HIGHLY recommended.
Thanks for the comments.
Does anyone know if this is done with soft goods (shoes and bags)?
this is common in footwear production, but may not be as many as 100prs. its called a pre-production trial. the idea is to teach the workers the correct working process (every shoe/pattern is different), and as you’ve suggested, to work out production workflow issues.
given that the production of a shoe is really a combination of maybe 100 steps (cutting, sitching, printing, lasting, assy, packing, etc.) there is really no other way that im familiar with to ensure good QC.
typically the production manager will work with the various sub manager for each stage, plus QC to go over different steps and note important points. the production process and best practices are then normally put together in a manual of sorts that will include a BOM, swatch cards, and notes for each part/step (ie. assembly order, skiving amount per part, lasting time/pressure, etc.).
sales samples are normally not done inline on the same production line, but often in a sample room or quasi production line that is quicker, with less workers and often more experienced workers to ensure that the SMS quantities are well made. sales samples are normally made a lot slower than production. (200prs per day vs. 2000 for example).
the process of qc and production should be the responsibility of the fty, but in many cases the brand may also have its own QC standards and also pre-production requirements for pairs, test, process.
keep in mind as i mentioned that each pair is essentially hand made…
R
ip_wirelessly is right.
This is very typical in high tech. Small Production Runs (SPRs) are effectively a mandatory aspect of the process. Getting in bed with your manufacturer as early as possible is HIGHLY recommended.
I work at one such place that does some small production runs, as part of the prototyping phase to continue testing and evaluations. They don’t go into full production until later, because usually changes are made after the 1st gen. Sometimes companies will run multiple SPR’s before they go to full production. It’s part of product development, it’s costly and it can create a lot of waste. 
Thank’s everyone for the replys.