[jonahhorowitz]

I worked at the Gap and Banana Republic all through high school and college. This was well known amongst the sales staff. There's a small amount of variation between each pair of jeans because of how they're cut and how the material stretches during cutting. Also just different people on different sewing machines makes a difference. We always advised customers to try on a few pairs of the size they were looking for to get one that fit best.

Here's a quick shot of what the cutting machine looks like: https://youtu.be/oBt85Jgjvng?si=UAU0Jj4q_Vztmi5K&t=680

[oniony]

I once took a pair of jeans back to Gap (UK) because they didn't fit. After trying on pairs for fifteen minutes I ended up on a pair that fitted perfectly, but which were the exact same size, style and fit. Weirdest experience exchanging an item for the exact same item.

[harimau777]

I'm surprised they even get as good of results as they do with those cutting methods. Aligning the direction of the threads (called the grainline) before cutting is extremely important. To the point that the approach they are taking almost seems like making a knowingly defective product.