There's offshore and "offshore"
Rob makes some excellent points for sure, and at the end of the day-these are personal decisions of value, for which there are no absolute answers.
Compounding the problem is this "offshore" issue..As has been posted, North ships material to Sri Lanka, the sails are built and shipped back-avoiding tax issues and high cost of labor. The sails are lower priced than the US counterparts. The price of this is some lowering of finished quality and flexibility in design (less customization for YOUR boat).
But this is not done the same way by everyone. Doyle frequently will order a "kit" from one of their offshore affiliates. The kit is really just panels cut by the computer cutter to a design sheet that was entered by email directly into the computer-so you get the benefit of the design YOU want for YOUR sail. These panels are rolled up and shipped to the US for assembly and finishing. There are some cost savings here, but not the same type of thing the as having the "built" in Sri Lanka. In fact, Doyle's offshore facilties are in Australia and NZ, so the labor is quite skilled and more expensive than you will find in a 3rd world country.
Quantum, on the other hand, has a HUGE affiliate in South Africa-which is a state of the art loft, and builds Mega and Maxi boat cruising and racing sails there for the non-US market, and for the US market, they build lower cost level cruising sails complete, mass produced production sails (Hunter, etc.) and some racing sail kits for the US. The exchange rate is what primarily helps out on price (or did when I was there), and also labor is less than in the US-but again, this is highly skilled labor making a high qaulity product.
Then there are levels. Even at the SA loft, the quality of the Hunter sails, from design and cut sheets to seaming and handwork is not the same as the cruising sails built for the recent Q customers on this site. The same loft can build sails of differing quality levels according to how they are sold and for what market.
The point being that this is a bit more complicated than it might seem and simply finding research that says the major sailmakers use offshore construction does not really tell the whole story, and the whole story is different for each sailmaker.
Is this reflected in the price? Generally. Q will give you US and SA pricing-although they may not call it as such. North wll certainly give pricing for US and Sri Lanka sails-they are entirely different products. Unfortunately for consumers, it is sometimes necessary to tease this info out of the sailmaker, since as someone correctly observed, the margins are VERY thin once discounts are applied, and sales guys are looking to maximize their commissions-hopefully while still giving the good products at fair prices.
So, while I understand Rob's points, the conclusion cannot be so general as to separate name brand, offshore, etc. The lines blur, and part of my goal is to help the members navigate this minefield so they can indeed get the best sails for their money-something that is hard to really know unless you have been through the process a few times-you can get burned no matter where you go.
Something that many owners do not realize is that if you are inexperienced, you might not even notice if, for example, the tack setback on your main is off by 2" and the wrinkle you see might not bother you enough to complain. This is what the real "offshore" cheapie guys count on-they build you a sail based on measurements you provide, so they are totally off the hook, and if the buyer does not know what to expect (and these are usually the ones who buy this stuff), they may not complain over a minor defect.
A name brand or local no name guy with a reputation to protect, will take his own dimensions, deliver the sail and MAKE SURE it is right (or they should). THEY know that knowledgeable sailors will see their product and if it is bad it won't be a secret, but if it is truly nice, that won't either.
Long winded and maybe we should kill this thread, but it is a complicated issue and there is much to take into account.
Best to all,
S