The Production Reality: Why Even the Best Factories Generate Second-Quality Batches

3. Inevitable Loss During Changeovers

Sanitary product factories typically switch between different specifications and sizes on the same production line—for instance, from size S to size M diapers, or from Baby Diapers to adult diapers. During changeovers, operators must replace certain tooling components, adjust folding mechanisms, and modify packaging dimensions. In the initial run following a changeover, products may exhibit dimensional alignment errors or packaging registration deviations. These products typically account for a very small fraction of the total batch and are separately classified and labeled as Grade B. This is a technical inevitability under multi-variant production models, not a sign of quality degradation.

4. Grading Management Reflects Quality Systems, Not Deficiencies

A factory that clearly labels, accurately records, and purposefully disposes of its Grade B products demonstrates a robust quality traceability system and strict grading standards. Conversely, if a factory claims it never produces second-quality goods, this should raise a red flag—it may mean the factory does not conduct sufficient testing, or releases all products as Grade A regardless of actual quality. For purchasers, understanding the root causes of Grade B generation helps establish reasonable quality expectations and make informed procurement decisions based on specific applications—such as high-frequency daytime change scenarios or institutional bulk use. Grade B is not a symbol of quality failure; it is a rational component of resource-efficient utilization within large-scale precision manufacturing.