Some cartons of our tees arrived with the wrong sizes mixed in or labels that do not match the size inside. How do we prevent and check this?
Size mix-ups start at cutting and bundling. Require size tickets and bundle control, check labels against measurements in inspection, and open cartons across the whole lot.
Customers report tees with a Large label that fit like a Medium, and a carton marked Large that contained Mediums. The factory says the cartons were counted correctly. How do we prevent and check this?
Main answer
A wrong-size problem has two forms. In one, the label says one size but the garment measures another. In the other, the garment and its label agree but the carton or polybag holds the wrong size. Both come from loss of control between cutting and packing, and both can be checked at inspection if you ask the right questions.
Where it starts
Garments are cut in sizes, tied into bundles with a ticket, sewn, labelled and packed. A size mix-up can happen when bundles are split or merged, when the wrong size label roll is loaded at the sewing station, or when pieces are repacked after a rework. A shortage in one size can also lead packers to fill cartons with another size to meet the total.
Controls to require
Ask the factory to explain how bundles and tickets are tracked, how label rolls are matched to size at the sewing line and how reworked pieces are re-verified. A line-clearance step, where the station is emptied of labels from the previous size before a new size starts, is a simple control to ask about. Ask for the packing list by carton, with sizes and quantities, and require it to be attached to each carton.
Check at inspection
Draw the sample from cartons across the whole lot, using a sampling plan such as ISO 2859-1, and check three things for every piece: the size on the label, the measured size against the spec and the size on the polybag or carton. Open cartons from different pallets, not just the top. Also check carton counts against the packing list. Treat a label that does not match the measured size as a defined defect class in your quality agreement.
Measure, do not trust
A garment can be correct to pattern and still seem the wrong size if the label is wrong, so measure key points on each size you sample, including chest width and body length, and compare with the spec sheet. If one size falls outside tolerance in several pieces, the problem may be in the pattern grade.
If it happens
Hold the lot, ask the factory to resort it by measured size, and confirm the fix with a new random sample before shipping.
Sources and further reading
Standards and rules are summarised from their published scope or official guidance. Use the current edition and confirm requirements for your market.
Three perspectives on this question
Purchasing perspective
I'd write size label control and a per-carton packing list into the PO, and ask the factory how they clear label rolls between sizes.
Merchandising perspective
A wrong size is a return that a customer remembers, so I'd treat it as a major defect, not a minor one.
QC perspective
We'd open cartons from several pallets and check label, measured size and carton marking on each sampled piece.
Working on a similar program?Send your tech pack, fabric references and test requirements. We reply with a quote and the questions we need answered.
Contact Knitwear BaseRelated products
Related articles
- Hoodie Sizing for Wholesale: Size Ratios That Protect Distributor Margins
- Private Label Clothing Manufacturer: Label, Care and Packaging Compliance by Market
- Garment Manufacturer China: How Factory Size and Structure Change What You Actually Get
- Clothing Manufacturer China: A Capability Map by Product Category, Not Another Evaluation Checklist
- Custom Clothing Labels and Hangtags: Care Labels, Woven Labels and Compliance Text
- Custom Clothing Packaging Manufacturer: Polybags, Cartons and Retail-Ready Presentation
- Clothing Factory Quality Control: Building a QC System Inside the Factory
- Garment Quality Inspection Process: Pre-Production, In-Line and Final Inspection Explained
- Questions to Ask a Clothing Manufacturer: The Questions and the Answers That Actually Matter
- How to Start a Private Label Clothing Brand: Assets, Sequence and First Order Economics
