Footwear

Quality Assurance and Quality Control for the Footwear Industry

With a lot of years’ experience in the footwear industry, Global Wits Consultancy Services presents a wide range of quality assurance and quality control solutions to shoe manufacturers and retailers.

In the footwear industry, fashion and comfort must always go hand in hand. In addition, shoe manufacturers and retailers must comply with international regulations and adapt their working methods to suit market expectations. This is challenging due to the complexity of the global footwear supply chain.

Global Wits Consultancy Services has helped companies match the quality of their shoes with international standards through our industry experience and technical expertise. Our team brings our expertise to bear on supplier qualifications and prototype development and to mass production and shipping. This allows our customers to ensure quality and reduce production delays. We control footwear quality and secure the supply chain of our clients with factory audits, QMS audits, social audits, ISO 14001 audits, shoe inspections, and supplier management service.

• Shoe Quality Control

The several parts of a shoe such as heels, soles, and laces, are often produced by different suppliers and then assembled elsewhere. This makes the production process complex and can lead to quality challenges. Quality defects in the footwear industry are often related to dimensions, excess glue, degumming, marks and dents, asymmetry, packaging, and incorrect labeling. During a quality control inspection of shoes, our inspector covers quantity, package and packaging, product style/construction, logo, labeling, markings, accessories, measurement, functional and performance tests, and more.

• Social Compliance

In factories with insufficient health and safety procedures and lack of compliance with regulations, workers can suffer from very harsh working conditions that lead to health and work-related harm. Other social compliance concerns include child labor and discrimination. A social audit allows a company to verify the compliance of a supplier and take the necessary corrective action. Several auditable standards apply to the footwear industry, including SA8000, WRAP, SMETA, and BSCI.

• Environmental Compliance

The footwear industry is increasingly adopting new materials and manufacturing methods to improve its environmental impact. The negative impact on the environment from conventional shoe manufacturing is mainly due to the processes and materials used. For example, in some countries, many chemicals are used for the tanning process and discharged into rivers, riverbanks, or near fields, thus polluting water and soil.
To ensure environmental compliance in their entire supply chain, companies need to audit their suppliers, implement environmental management systems such as ISO 14001, and take the necessary actions to improve their impact on the environment. Global Wits Consultancy Services provides ISO 14001 gap analysis audits, preparation for certification, and consulting services.

Our Application

Global Wits Consultancy Services’s broad range of Quality Assurance (QA) and Quality Control (QC) solutions for the footwear industry can be applied to improve factory performance or to control the quality of your product categories such as:

• Leather footwear
• Rubber footwear
• Textile footwear
• Footwear parts

Quality Assurance and Quality Control Services for shoes.

Manufacturing Audits and Advisory

Take advantage of our end-to-end comprehensive approach to improve your supply chain performance.

• Manufacturing Process Audits
• Process Improvement
• Production Capacity Analysis (Run & Rate)
• Quality Investigation (root cause investigation of a defective product)
• Root Cause Analysis
• Corrective Action Follow-Up
• Process Failure Mode Effects Analysis (PFMEA)
• Continuous Improvement

Global Wits Consultancy Services is a global quality assurance company that offers manufacturing process audit solutions across five continents. We help qualify suppliers, validate production line processes, and investigate the root causes of defects.

In our experience, the quality performance of a good factory varies by production lines due to multiple factors such as people, equipment, materials, methods, production environment, and a plethora of other factors.

Global Wits Consultancy Services’s Manufacturing Process Audit focuses on assessing the specific production line that is or will be producing your product. The assessment will assess the quality practice of a product from incoming material, through to every single stage of the production process, including material handling, in-process quality control activities, outgoing QA, and warehousing.

The outcome of the Manufacturing Process Audit is a thorough manufacturing audit report which includes a risk-based process control analysis of the factory. The report consists of Global Wits Consultancy Services’s risk recommendations, on-site observations, performance scores, and high-resolution photos. The report will be used by supply chain and quality professionals to make better-informed decisions about the finer details of their supplier for factory performance.

Supplier and Factory audits

Global Wits Consultancy Services’s range of comprehensive audits for the footwear industry include:

• Supplier Verification
• Supplier Quality Audits
• ISO 9001 Quality Management System Audits
• ISO 14001 Environmental Management System Audits
• ISO 45001 Management Systems of Occupational Health and Safety Audits
• Social Compliance Audits: SA8000, WRAP, SMETA, BSCI
• Supply Chain Security Audits
• Combined Audits

Factory and supplier audits are systematic evaluations conducted to assess manufacturers’ or suppliers’ quality management systems, operational capabilities, and compliance levels.

Global Wits Consultancy Services offers tailored factory and supplier audit services. As a trusted partner, Global Wits Consultancy Services supports businesses that need to:

• Verify the reliability and capabilities of new suppliers
• Ensure supplier compliance with standards and industry best practices
• Prepare a factory for a certification audit or maintain existing certification
• Meet client compliance requirements
• Identify non-compliance issues and implement corrective and preventive actions
• Improve factory manufacturing performance to achieve quality excellence

Footwear Quality Inspection Services

Our quality control inspections for shoes include:

• First-Article Inspections (FAI) are performed prior to mass production. Product properties are measured and compared with specifications to verify quality matches.
• In-Process Inspections (IPI) ensure that the processes and techniques used to manufacture textile and garments are followed.
• Pre-Shipment Inspections (PSI) verify the conformity of textile to specifications before shipping. Inspectors evaluate workmanship, functionality, packaging, labeling, and other criteria as required.
• Container Loading Supervision (CLS) ensures that proper methods are employed during product loading, and counts are verified on-site.
• Sorting services are used to inspect production and detect quality issues or perform rework operations.

For third-party quality inspection services, Global Wits Consultancy Services recommends the International Inspection Standard ANSI Z.1.4-2003 (ANSI Sampling Table) to determine the number of units that will be randomly selected for evaluation.

Samples are checked against a detailed inspection plan for appearance, applicable functionality, packaging integrity, workmanship, and the client’s specific requirements. Discovered defects are classified as major, minor, or critical depending on the inspection plan. We have no concern to follow our customer’s QC standards, procedures, and documentation.

Global Wits Consultancy Services’s quality control inspection services apply to all industries and are tailored to the requirements of each project. From 100% to AQL-based inspections, our solutions cover the entire spectrum of quality inspections and include First Article Inspections (FAI), In-Process Inspections (DUPRO), Pre-Shipment Inspections (PSI), and Container Loading Supervision (CLS).

Our product inspection reports and results with digital photos are delivered to our clients within 24 hours of the service through our secure online client center so that product shipments can be quickly authorized.

Advantages of QC Inspections

1. Avoid Costly Product Defect and Shipment Delays: Quality control (QC) inspections minimize the number of costly defects by detecting non-conformances throughout the production cycle before it is too late.

2. Identify or Explore Corrective Actions: Product quality inspection services help companies determine the overall quality of their order, and determine the need to issue corrective actions before any products leave the factory.

3. Protect Brand and Reputation: Sub-standard products result in customer complaints and damage brand reputation. Third-party product quality inspections help ensure consistent customer satisfaction and maintain brand integrity.

Our Range of Third-Party Quality Inspection Services

Quality and purchasing departments demand that their suppliers meet high product quality specifications. As a global third-party inspection company, Global Wits Consultancy Services offers quality solutions throughout the entire production cycle. This allows our customers to identify defects, ensure product quality, and reduce the cost of poor quality.

Global Wits Consultancy Services’s local quality control inspectors and quality consultants work in partnership with our clients and are deployed accordingly to the project requirements and their specialization. Our team includes specialized quality inspectors in textile, footwear, furniture, medical devices, electrical, electronics, automotive, mechatronics, mechanical, welding, coating, painting, piping, and more.

Our range of quality control inspection services include:

• First-Article Inspections (FAI): As a global third-party inspection company, Global Wits Consultancy Services inspects first-article samples prior to volume production. This inspection in quality verifies that product specifications are being met and avoids unnecessary reengineering work later.
• In-Process Inspections (IPI/DUPRO): An in-process QC inspection, also called: During Production inspection, evaluates random samples from production lots when the process is circa 20-30% complete. This confirms the product quality and allows any necessary changes to be addressed early on, reducing rework time and costs.
• Pre-Shipment Inspections (PSI): During a pre-shipment inspection, our engineers verify that finished goods conform to the most stringent specifications. A pre-shipment inspection (PSI) generally occurs when production is 100% complete and packaging is 80% complete. For example, if an automotive product or auto part inspection is required, we would request the specifications and golden samples in advance. These would then be used to ascertain the quality of the products produced at the supplier. Pre-shipment inspections are also known as pre-dispatch inspections.
• Container Loading Supervision (CLS): Global Wits Consultancy Services ensures that proper methods are employed during product loading, and we verify counts on-site. Products conformance to international standards will also be verified.

Supplier Management

Global Wits Consultancy Services’s Supplier Management Solutions enhance compliance and performance of the entire supplier portfolio by:

• Performing an on-site risk assessment
• Establishing a corrective action plan
• Verifying corrective action implementation through detailed follow-up activities
• Scheduling subsequent annual visits based on supplier risk level
• Providing a supplier portfolio dashboard and performance analysis

Our supplier management team will create a customized checklist that meets even the most exacting requirements. The supplier management service is particularly suitable for small QA teams with a large supplier base across the globe. Global Wits Consultancy Services assists these teams in investigating and resolving compliance and quality issues in a timely and cost-effective manner.

Buyers, procurement managers and quality managers play a vital role in ensuring supplier quality. This encompasses proactive performance monitoring to identify and mitigate costly risks and errors.

Global Wits Consultancy Services offers a robust set of services to ensure supplier quality, which we call the Supplier Management Toolkit. The toolkit is designed to help anyone managing supplier quality to navigate the challenges of meeting supplier compliance and quality standards and delivering quality products.

Our stage-based Sourcing Lifecycle applies to virtually any product or component, guiding you from new product development to outgoing QC and shipment.

Below, we outline each stage of the sourcing journey and highlight the common risks and challenges faced in supplier management, helping you safeguard your supply chain and uphold your brand’s reputation.

Development & Planning;

 1. New Product Development

New product development lays the foundation for strategic sourcing. Prototyping is crucial to validate that the supplier understands the client’s requirements.

Global Wits Consultancy Services inspections validate the new parts while our supplier development services align quality expectations with suppliers and strengthen their ability to meet quality requirements and reduce time to market.

Global Wits Consultancy Services’s Quality Solutions:

 First Article Inspection (FAI)
 Supplier Development Services
 Resident Supplier Quality Resourcing

Supplier Risks & Challenges:

 Poor communication of technical details between buyers and factories
 Misalignment of product specifications and critical design requirements among buyers, suppliers, and factory production teams
 Inadequate consideration of advanced product quality planning
 Challenges when transitioning from prototype suppliers to mass-manufacturing suppliers
 Misalignment on design and engineering revisions

 2. Supplier Selection

Once the component specifications are defined, the procurement department identifies a list of suitable suppliers that can potentially meet their capability, cost, capacity, and quality requirements.

Global Wits Consultancy Services offers a range of supplier due diligence and supplier evaluation support. Our experts visit suppliers to assess their capabilities, mitigate the risk of scams, overpromises, and miscommunication, and validate their credentials, trustworthiness, and financial stability.

Global Wits Consultancy Services’s Quality Solutions:

 Supplier Quality Audits
 QHSE Audits
 ESG Audits
 Onsite Supplier Verification
 Financial Credit Check

Supplier Risks & Challenges:

 Lack of experience and due diligence in new supplier region
 Communication challenges
 Concern about supplier scams
 Low confidence supplier’s trustworthiness
 Concerns over supplier’s financial viability

 3. Supplier Qualification

A world-class organization usually has a comprehensive supplier qualification program to identify and mitigate the risks associated with quality, safety, on-time delivery, cost, and compliance.

Global Wits Consultancy Services establishes a global audit program to systematically onboard new suppliers, categorize their risk levels, and establish a reaction plan based on the supplier’s performance on quality systems, environmental management, and social and ethical compliance.

Global Wits Consultancy Services’s Quality Solutions:

 Global Supplier Audit Programs
 Supplier Quality Audit for Potential Suppliers
 Quality Management System Audit
 Social & Ethical Audits
 Supply Chain Security Audit
 Environmental Audit

Supplier Risks & Challenges:

 Suppliers are not as capable as they initially claimed
 Supplier lacks effective and systematic quality assurance practice
 Supplier is ISO 9001 certified, but the underlying principles are not implemented in practice
 Mass production quality does not match prototype quality
 Buyers want to sell to big retailers, but their suppliers do not yet comply with the retailer’s supplier code of conduct
 Supplier violation on labor law, ethical and environmental compliances
 Goods held in customs due to supply chain security malpractice

 4. Pre-Production Validation

Before commencing volume production, it is crucial to validate that the equipment, staffing, production methods, capacity, and quality control plan are in place for each product line.

Global Wits Consultancy Services offers on-site quality support to prevent and reduce the potential cost of poor quality (COPQ) and risk, ensuring a smooth transition from product development to mass production.

Global Wits Consultancy Services’s Quality Solutions:

 Engineering Build (EB) and Quality Build (QB) Audit
 First Article Inspection (FAI)
 APQP/PPAP Audit
 Manufacturing Process Audit 
 Resident Supplier Quality Resourcing

Supplier Risks & Challenges:

 Factory not ready for mass production
 Shipment delays due to critical failure, poor quality, and resource constraints
 An exponential increase in defective products
 Product recall
 High Cost of Poor Quality
 An exponential increase in the cost of change after mass production commences

Production & Delivery

 5. Production Planning

Production planning ensures that the supplier has sufficient raw materials, components, and staff and that other outsourced processes meet the specified schedule.

Global Wits Consultancy Services offers assistance in timely supplier communication, onsite visits, and daily or weekly monitoring reports. This minimizes the risks of delays from ineffective procurement planning, staff shortages, or sub-supplier mismanagement.

Global Wits Consultancy Services’s Quality Solutions:

 Order Expediting
 Resident Supplier Quality Resourcing

Supplier Risks & Challenges:

 Production delay due to poor material procurement planning
 Production delay due to inadequate production staffing
 Poor sub-supplier management

 6. Incoming Quality Control

Incoming inspection reflects a factory's commitment to quality control from the outset. Understanding how a factory manages its incoming material and its supply chain is a very good indication of its commitment to quality.

Global Wits Consultancy Services quality solutions address issues such as defect acceptance, material substitutions, and component decay due to poor practices or storage conditions.

Global Wits Consultancy Services’s Quality Solutions:

 Incoming Inspection
 In-Process Inspection
 Manufacturing Process Audit 

Supplier Risks & Challenges:

 The factory does not manage the quality of its supply chain or is poor at supplier management
 Suppliers turn a blind eye to defective components during incoming and still use them for production and assembly
 Using sub-standard material or components (e.g., lower-quality fabric than required)
 Substituting lower-cost alternatives for product components (e.g., cheaper electronic components in a mobile phone)
 “Quality fade” where suppliers make small, gradual substitutions in materials and components over time
 Bulk material ordered by the supplier degrades over time due to poor storage conditions

 7. Production and Assembly

Many things can go wrong during mass production due to machine failure, lack of process control, and operator mistakes. While it is normal for defects to occur, these defects must be detected and contained.

Global Wits Consultancy Services offers a range of support to verify control plan adherence, early defect detection, quality improvement, and issue resolution through monitoring, investigations, and CAPA validation.

Global Wits Consultancy Services’s Quality Solutions:

 First Article Inspection (FAI)
 In-Process Inspection
 Manufacturing Process Improvement
 Quality/Root Cause Investigation (8D)
 CAPA Verification
 Order Expediting
 End-Of-Line Testing & inspection
 Resident Supplier Quality Resourcing

Supplier Risks & Challenges:

 Operators are not producing according to the production control plan
 Supplier is under pressure to ship goods, turning a blind eye to defective components
 Lack of quality staff to enforce quality control
 Poor control of re-worked material/product
 Mistakes made by temporary, untrained staff/operators
 Communication breakdown when the supplier is under pressure

 8. Outgoing QC & Shipping

The smallest aesthetic defect on the packaging or missing components can lead to customer returns, while a misplaced label may result in compliance issues. Outgoing Quality Control is the last line of defense before products are properly loaded into containers for shipment.

Global Wits Consultancy Services offers pre-shipment inspections and end-of-line testing to ensure your products meet your quality requirements and reduce the chance of returns or re-work.

Global Wits Consultancy Services’s Quality Solutions:

 Manufacturing Process Audit
 Poka-Yoke Implementation
 Pre-Shipment Inspection
 End-Of-Line Testing & inspection
 Container Loading Supervision
 C-TPAT Audit

Supplier Risks & Challenges:

 Products are poorly packaged
 Human mistakes and missing components lead to customer returns
 Wrong labeling leads to compliance issues and significant re-work
 Rough handling of goods during container loading by the factory or outsourced warehouse, leading to damaged product
 Poor container loading leads to product damage during transit

Why Global Wits Consultancy Services?

Partnership

Global Wits Consultancy Services genuinely sees your company and your suppliers as partners looking for growth and improvement. We don’t just give pass/fail results. We provide professional recommendations, facilitation, and performance management to achieve the desired results.

Quality Dashboard

Global Wits Consultancy Services’s Quality Dashboard provides a holistic dashboard view of your supplier portfolio including data analytics to better understand and determine the next action required at your supplier.

Experience & Expertise

Global Wits Consultancy Services has overseen successful supplier transformation projects helping companies from the packaging industry achieve their quality goals.

Global Presence

Global Wits Consultancy Services has agile teams of inspectors and auditors a lot of countries ready to meet your quality assurance needs whether it’s a packaging quality inspection or a comprehensive factory audit.