13 Garment Defect Analysis

APPAREL STANDARDS SPECIFICATION AND QUALITY CONTROL DEFECT ANALYSIS OF 4 GARMENTS

NOVEMBER 10, 2010

SHIRT DEFEC T NO.

DEFECT NAME

LOCATION

CAUSE

REMEDY DEPARTME NT

1.

IMPROPER POSITIONING OF SIZE LABEL

UNDER YOKE

OPERATOR INEFFICIENCY

OPERATOR TRAINING

SEWING/MARKING

2.

IMPROPER ATTACHMENT OF SIZE LABEL

UNDER YOKE


OPERATOR TRAINING

SEWING

3.

IMPROPER POSITIONING OF BRAND LABEL

UNDER YOKE


OPERATOR TRAINING

SEWING/MARKING

PICTURE

4.

DAMAGED BUTTONHOLE

COLLAR, CUFF

BLUNT KNIFE OR IMPROPER STITCH DENSITY

REPLACE KNIFE/USE PROPER STITCH DENSITY

SEWING

5.

IMPROPER STITCH IN THE DITCH

COLLAR, CUFF, YOKE


OPERATOR TRAINING

SEWING

6.

IMPROPER TOP STITCH


OPERATOR TRAINING

SEWING

7.

UNTRIMMED THREAD

COLLAR & COLLAR BAND ATTACH, ARMHOLE, HEMLINE, CUFF PLACKET, BUTTONHOLE PLACKET, SLEEVE, CUFF HEM BRAND LABEL, SIDE SEAM, BUTTONHOLE PLACKET, UNDER POCKET, CUFF BUTTON

IMPROPER INSPECTION

PROPER INSPECTION

FINISHING

8.

STAINS

COLLAR, LEFT FORNT POCKET,WASHCA RE LABEL, YOKE

MISHANDLING

PROPER HANDLING

FINISHING

9.

BUBBLING

COLLAR, CUFF PLACKET

IMPROPER FUSING

FUSING

10.

PILLING

COLLAR

IMPROPER HANDLING/ FABRIC WITH PILLS

PROPER FUSING CONDITIONS – HEAT, TEMPERATUR E& PRESSURE PROPER HANDLING/ CHECKING FABRIC TO BE USED

11.

MISSING BUTTON

COLLAR, RIGHT CUFF, BOTTON PLACKET

IMPROPER ATTACHMENT/ MISHANDLING

12.

SEAM PUCKER

SIDE SEAM, SLEEVE UNDERARM

OPERATOR INEFFICIENCY/ WRONG FEED

FINISHING/ INVENTORY

PROPER SEWING/ FINISHING ATTACHMENT/ PROPER HANDLING

OPERATOR TRAINING/ RIGHT FEED MECHANISM

SEWING

13.

DIRTY GARMENT

WHOLE GARMENT

GARMENT NOT WASHED PROPERLY

PROPERLY WASH GARMENT

FINISHING

14.

SEAM MISMATCH

RIGHT ARMHOLE

OPERATOR INEFFICIENCY/ WRONG FEEDING

OPERATOR TARINING/ RIGHT FEED MECHANISM

SEWING

15.

IMPROPER BUTTON ATTACHMENT

BUTTON PLACKET, CUFF PLACKET

POSITON NOT MARKED PROPERLY

MARK POSITION PROPERLY

MARKING

16.

WRONG POSITION OF FUSING

BUTTONHOLE PPLACKET

IMPROPER INTERLININ ALIGNMENT

PROPER LINING ALIGNMENT

SEWING

17.

UNEVEN STITCH DENSITY

BUTTON PLACKET

OPERATOR INEFFICIENCY – UNEVEN THREAD TENSION

OPERATOR TRAINING – PROPER THREAD TENSION

SEWING

18.

STAGGERED STITCH

COLLAR & COLLAR BAND ATTACHMENT, DIAMOND PLACKET, YOKE TOPSTITCH


OPERATOR TRAINING

SEWING

19.

BACK TACK ABSENT

MANY SEAMS


OPREATOR TRAINNING

SEWING

20.

IMPROPER BACK TACK

MANY PLACE


OPERATOR TRAINING

SEWING

21.

ASSYMETRICAL POCKET SHAPE

POCKET

INCORRECT PATTERN/ IMPROPER CUTTING

CORRECT PATTERN/ PROPER CUTTING

CUTTING

22.

POCKET PLACEMENT

LEFT FRONT

INCORRECT MARKING

CORRECT MARKING

MARKING

23.

PEN MARKS

LEFT FRONT POCKET, COLLAR, WASHCARE LABEL

IMPROPRER HANDLNIG

PROPER HANDLING

CUTTING/ FINISHING

24.

THREAD COLOUR VARIATION

SIDE SEAM


OPERTAOR TRAINING

SEWING

25.

CREASE

SLEEVE

IMPROPER IRONING

PROPER IRONING

FINISHING

26.

UNCUT SELVEDGE

LEFT CUFF PLACKET



CUTTING

27.

SKIP STITCH

SLEEVE, RIGHT CUFF

IMPROPER MACHINE SETTING

PROPER MACHINE SETTING

SEWING

28.

TWISTED SEAM

BOTTOM HEM


OPERATOR TRAINING

SEWING

29.

IMPROPER FOLDING

BUTTONHOLE PLACKET


OPERATOR TRAINING

SEWING

30.

WRONG FABRIC INLAY

LEFT SIDE SEAM, LEFT ARMHOLE


OPERATOR TRAINING

SEWING

31.

HIKING

FRONT



PATTERN MAKING/ CUTTING

32.

COLLAR BONE ATTACHMENT

COLLAR


OPERATOR TRAINING

SEWING

33.

UNDESIRED PLEAT FORMATION

SIDE SEAM


OPERATOR TRAINING

SEWING

34.

UNEVEN BUTTON PLACEMENT

CUFF PLACKET

IMPROPER POSITIONING/ INCORRECT MARKING

PROPER POSITIONING/ CORRECT MARKING

SEWING/ MARKING

35.

UNEQUAL LENGTH

SLEEVE, SLEEVE PLACKET

IMPROPER CUTTING/ FOLDING

PROPER CUTTING/ FOLDING

CUTTING/ SEWING

36.

IMPROPER SHAPE

CUFF

IMPROPER CUTTING/ INCORRECT PATTERN

PROPER CUTTING/ CORRECT PATTERN

CUTTING/ PATTERN

37.

FRAYED EDGES IN STITCH

SIDE SEAM, HEM EDGE FINISHING/ PROPER FOLDING NOT DONE

EDGE FINISHING/ PROPER FOLDING

SEWING

38.

VISIBLE RAW EDGES

DIAMOND PLACKET, LEFT ARMHOLE

IMPROPER FOLDING/ SEAMING

PROPER FOLDING/ SEAMING

SEWING

39.

SOILING

WHOLE GARMENT

IMPROPER HANDLING

PROPER HANDLING

ALL

40.

BAD ODOUR

WHOLE GARMENT

NOT WASHED PROPERLY

WASH PROPERLY

FINISHING

T-SHIRT DEFECT.N O.

DEFECT

LOCATION

CAUSE

REMEDY DEPARTMEN PICTURE T

1.

OPEN SEAM

HEM

OPERATOR INEFFICIENCY/ IMPROPER THREAD TENSION

OPERATOR TRAINING/ PROPER THREAD TENSION

SEWING

2.

HOLE

FRONT, LEFT SLEEVE

FABRIC DEFECT/ IMPROPER HANDLING

CHECK FABRIC/ PROPER HANDLING

INVENTORY/ FINISHING

3.

SEAM MISMATCH

ARMHOLE

OPERATOR INEFFICIENCY/ INCORRECT FEED

OPERATOR TRAINING/ CORRECT FEED

SEWING

4.

BROKEN STITCH

SLEEVE

WEAK THREAD/ INAPPROPRIATE TENSION

GOOD QUALITY THREAD/ PROPER THREAD TENSION

SEWING

5.

CRACKED PRINT

BACK & FRONT, NEAR HEMFRONT, RIGHT SLEEVE

IMPROPER PRINTING/ IMPROPER IRONING

PROPER PRINTING/ PROPER IRONING

PRINTING/ FINISHING

6.

IMPROPER POSITIONING OF SIZE LABEL

BELOW NECKLINE

OPERATOR INEFFICIENCY/ IMPROPER MARKING

OPERATOR TRAINING/ PROPER MARKING

SEWING/ MARKING

7.

SHADE VARIATION

WHOLE GARMENT

IMPROPER DYEING/ EXCESSIVE IRONING

PROPER DYEING/ PROPER IRONING

DYEING & FINISHNG

8.

HIKING

FRONT & BACK




9.

TILTED BRAND LABEL

B ACK


OPERATOR TRAINING

PRINTING

10.

UNEQUAL SLEEVE LENGTH

RIGHT & LEFT

INCORRECT PATTERN/ IMPROPER CUTTING/ OPERATOR INEFFICIENCY

CORRECT PATTERN/ PROPER CUTTING/ OPERATOR TRAINING

PATTERN MAKING/ CUTTING/ SEWING

11.

TWISTED SEAM

RIGHT SLEEVE, SIDE SEAM

OPERATOR INEFFICIENCY/ IMPROPER FEEDING

OPERATOR TRAINING/ RIGHT FEED

SEWING

12.

IMPROPER FABRIC INLAY

HEM

DIFFERNTIAL FEEDING OF FABRIC PARTS

USE OF APPROPRIATE FEED DOG

SEWING

13.

SKIP STITCH

COLLAR BAND

OPERATOR INEFFICIENCY/ IMPROPER THREAD TENSION

OPERATOR TRAINING/ PROPER THREAD TENSION

SEWING

14.

UNEQUAL PRINT DENSITY

FRONT, BACK, RIGHT SLEEVE

UNEQUAL PRINT PASTE APPLICATION

PROPER PRINTING TECHNIQUE

PRINTING

15.

PENETRATION OF PRINT PASTE

FRONT

IMPROPER IRONING

PROPER IRONING

FINISHING

16.

UNCUT THREAD

ARMHOLE, SIDE SEAM, WASHCARE LABEL


OPERATOR TRAINING

FINISHING

17.

FOREIGN THREAD

ARMHOLE,SIDE SEAM


OPERATOR TRAINING

FINISHING

18.

SEAM LINE MISMATCH

LEFT SIDE SEAM & HEM


OPERATOR TRAINING

SEWING

19.

BAD ODOUR

WHOLE GARMENT

NOT WASHED PROPERLY

WASH PROPERLY

FINISHING

20.

DIRTY GARMENT

WHOLE GARMENT

NOT WASHED PROPERLY

WASH PROPERLY

FINISHING

DENIM DEFEC T NO.

DEFECT NAME

LOCATION

CAUSE

REMED DEPARTMEN Y T

1.

BUTTONHOLE DAMAGED

WAISTBAND

BLUNT KNIFE OR IMPROPER STITCH DENSITY

REPLACE KNIFE/USE PROPER STITCH DENSITY

SEWING

2.

BRAND LABEL DAMAGED

WAISTBAND

IMPROPER HANDLING/ IMPROPER IRONING

PROPER HANDLING/ PROPER IRONING

FINISHING

3.

SIZE LABEL DAMAGED

UNDER WAISTBAND

IMPROPER HANDLING/ IMPROPER IRONING

PROPER HANDLING/ IMPROPER IRONING

FINISHING

PICTURE

4.

UNCUT THREAD

WAISTBAND, BELT LOOP, BRAND LABEL, POCKET, BACK


OPERATOR TRAINING

SEWING

5.

SKIP STITCH

WAISTBAND

IMPROPER MACHINE SETTING

PROPER MACHINE SETTING

SEWING

6.

BROKEN STITCH

BRAND LABEL UNDER WAISTBAND

WEAK THREAD/ INAPPROPRIATE TENSION

GOOD QUALITY THREAD/ PROPER THREAD TENSION

SEWING

7.

IMPROPER BACKTACK

ZIPPER, WAISTBAND


OPERATOR TRAINING

SEWING

8.

MISSING BARTACK

RIGHT FRONT POCKET


OPREATOR TRAINING

SEWING

9.

IMPROPER J STITCH

ZIPPER


OPREATOR TRAINING

SEWING

10.

IMPROPER TOPSTICH

WAISTBAND, BOTH SIDE SEAM, HEM, POCKET


OPREATOR TRAINING

SEWING

11.

EXTRA STITCH

BRAND LABEL


OPREATOR TRAINING

SEWING

12.

MISSING RIVET

RIGHT FRONT POCKET

IMPROPER HANDLING

PROPER HANDLING

FINISHING

13.

SEAM MISMATCH

CROTCH


OPREATOR TRAINING

SEWING

14.

STAGGERING STITCH

CENTRE BACK


OPREATOR TRAINING

SEWING

15.

YARN UNRAVELLING

BACK LEFT POCKET

IMPROPER HANDLING

PROPER HANDLING

FINISHING

V

16.

UNEQUAL LENGTH

BELT LOOP




17.

FAULTY GRAIN

POCKET PIPING



MARKER MAKING/ SPREADING/ CUTTING

18.

UNEQUAL WIDTH

BACK POCKET PIPING



CUTTING/ SEWING

19.

STAIN MARKS

POCKET, RIGHT FRONT

MISHANDLING

PROPER HANDLING

SEWING/ FINISHING

20.

PEN MARKS

LEFT FRONT

IMPROPER HANDLING

PROPER HANDLING

CUTTING/ FINISHING

21.

CREASE

BACK POCKET, POCKET FABRIC

IMPROPER IRONING

PROPER IRONING

FINISHING

22.

GRIN

ZIPPER

IMPROPER THREAD TENSION

PROPER THREAD TENSION

SEWING

23.

SEAM LINE MISMATCH

SIDE SEAM AND HEM


OPERATOR TRAINING

SEWING

24.

IMPROPER FOLDING

HEM


OPERATOR TRAINING

SEWING

25.

TWISTED SEAM

HEM


OPERATOR TRAINING

SEWING

26.

IMPROPER THREAD COUNT & STITCH DENSITY

HEM


OPERATOR TRAINING

SEWING

27.

PILLING

POCKET FABRIC

IMPROPER HANDLING/ FABRIC WITH PILLS

PROPER HANDLING/ PROPER HANDLING/ CHECKING FABRIC TO BE USED

FINISHING

28.

FOREIGN MATERIAL

SIDE SEAM OVERLOCK


OPERATOR TRAINING

SEWING

29.

EXTRA FABRIC INLAY

POCKET

DIFFERENTIAL FEEDING OF FABRIC PARTS

USE OF APPROPRIAT E FEED DOG

MARKER MAKING/ CUTTING

30.

UNEQUAL HEM ROUND

HEM PANELS


OPERATOR TRAINING

SEWING

31.

IMPROPER SERGING

INSEAM, SIDE SEAM


OPERATOR TRAINING

SEWING

32.

SLACK STITCH

BELT LOOP


OPERATOR TRAINING

SEWING

33.

BAD ODOUR

WHOLE GARMENT

WHOLE GARMENT

NOT WASHED PROPERLY

FINISHING

34.

SOILING

WHOLE GARMENT

IMPROPER HANDLING

PROPER HANDLING

FINISHING

SKIRT DEFEC DEFECT NAME LOCATION T NO.

CAUSE

REMEDY

DEPARTME NT

1.

MISSING FASTNER

WAISTBAND


OPERATOR TRAINING

INVENTORY/ SEWING/ FINISHING

2.

UNCUT THREAD

WHOLE GARMENT


OPERATOR TRAINING

SEWING

3.

RAW EDGES VISIBLE

WHOLE GARMENT


OPERATOR TRAINING

SEWING/ FINISHING

PICTURE

4.

IMPROPER FOLDING

HEM


OPERATOR TRAINING

SEWING

5.

TWISTED SEAM

HEM


OPERATOR TRAINING

SEWING

6.

IMPROPER TOPSTICH

WAISTBAND, HEM


OPERATOR TRAINING

SEWING

7.

YARN FAULTS

SCATTERED IN GARMENT

DEFECTIVE FABRIC/ IMPROPER HANDLING

PROPER FABRIC/ PROPER HANDLING

INVENTORY/ FINISHING

8.

IMPROPER STITCH DENSITY

WHOLE GARMENT


OPERATOR TRAINING

SEWING

9.

NOT UNIFORM GSM


DEFECTIVE FABRIC

PROPER FABRIC

INVENTORY

10.

SEAM NOT PRESSED OPEN

SEAM


OPERATOR TRAINING

FINISHING

11.

THICK THREAD


DEFECTIVE FABRIC

PROPER FABRIC

INVENTORY

12.

IMPROPER LENGTH

WAISTBAND



PATTERN/MARKER MAKING/ CUTTING

13.

UNCUT SELVEGDE

UNDER FRONT & BACK



CUTTING

14.

SKIP STITCH

WAISTBAND


OPERATOR TRAINING

SEWING

15.

STAIN

WAISTBAND, HEM

IMPROPER HANDLING

IMPROPER HANDLING

FINISHING

16.

GRIN

GORE PANEL

IMPROPER THREAD TENSION

APPROPRIATE THREAD TENSION

SEWING

17.

SEAM LINE MISMATCH

GORE PANEL & HEM


OPERATOR TRAINING

SEWING

18.

IMPROPER SEAM DIRECTION

GORE PANEL


OPERATOR TRAINING

SEWING

19.

BAD ODOUR

WHOLE GARMENT

NOT WASHED PROPERLY

WASH PROPERLY

FINISHING

20.

SOILING

WHOLE GARMENT

WHOLE GARMENT

IMPROPER HANDLING

CUTTING/ FINISHING

13 Garment Defect Analysis

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