We monitor every stage of production in real time — cut, last, stitch, QC, pack. AI flags deviations the moment they happen, not after the carton is sealed.
Pattern alignment is verified against a digital master. Any deviation beyond 0.5mm triggers an immediate flag before the leather moves to the next bench.
Sole alignment and heel positioning are checked against spec. Asymmetry and adhesion gaps are flagged in real time by visual sensors on the last bench.
Stitch tension, stitch count per inch, and thread colour consistency are monitored continuously. Variance beyond spec triggers a stop-and-check alert.
AQL 2.5 inspection, automated. Colour deviation, sole separation, embellishment check, and finish consistency — all scored and logged before a pair advances to packing.
Batch completion is verified against the order spec. Size assortment, box labelling, and carton count are all cross-checked before a batch is marked dispatch-ready.
Each production line runs independently with its own AI monitor. Flags from any line surface instantly.
Loose or tight stitching that changes under wear. AI detects thread tension deviation per stitch cycle.
72% of stitch-stage flagsAdhesion failure between upper and sole. Detected by gap sensor at the lasting press before bonding sets.
54% of lasting-stage flagsDye lot inconsistency between pairs in the same batch. Colour delta is compared to the approved lab dip.
48% of QC-stage flagsGrain or texture misalignment across paired components. Flagged before the leather is cut, saving material.
38% of cut-stage flagsMissed stitch cycles that create structural weak points. Vision sensor counts stitches per inch in real time.
29% of stitch-stage flagsWrong size in a carton. Barcode scan at packing verified against the order pick list before the box seals.
18% of pack-stage flagsEvery order we take is monitored this way — it's not a premium add-on, it's just how we work.