Many designers and brands tend to leave one of the most important aspects of managing their product until the very end of the manufacturing process: quality control. Little mistakes that were made during the sample process that were not addressed during development can add up to big issues if a faulty pattern is graded out to larger sizes and then cut.
The most important thing to do is make sure that your samples and development are at the quality level you want before going into production, and that you are making cost-efficient design decisions that eliminate waste or unnecessary construction complexities. There are already many industry standard checks and balances that are built into the production system to mitigate against any big disasters. Even if they cost a bit more money at the time, they are often worth it. For example, all styles should have an approved Pre-Production sample before the final pattern is graded and marked. And likewise, after cutwork has been completed, one TOP (Top of Production) sample should be approved for construction standards before final lot is sewn.
Now, does this mean things with never go wrong or that mistakes won’t ever happen? No—this is part and parcel of the manufacturing industry, managing issues and solving them as they arise. But a quality control system that starts at the beginning of the development process, long before you even begin to grade and mark your final patterns for production, will seriously reduce issues and mistakes that can lead to lost money, wasted time, and strained relationships with your vendors and factories.