Garment Defects List

July 14, 2017 | Author: TAPEBALL9736 | Category: Seam (Sewing), Sewing, Textiles, Yarn, Textile Arts
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Famous Textile Table QC defects list

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Introduction Garment defects can be separated into 3 categories: ➢

Fabric defects. 



Workmanship and handling defects. 



These are defects that are found in the fabric, mostly these are not caused by the sewing lines. These are defects that are directly caused by production section, this would include both the cutting and sewing section.

Trims, accessories and embellishment defects. 

These defects include things like labels, color of sewing thread, screen print and embroidery designs and placements.

Defects must also be classified into ➢

Critical 



Major 



Critical defects are defects that are not allowed to be shipped and are the most serious of defects (0%). Major defects are serious defects that are not allowed over a certain percentage (3%) depending on buyers requirements.

Minor 

Minor defects are defects that are not allowed over a certain percentage depending on buyers requirements. (5%).

Fabric defects Fabric defects should be addressed at the point of fabric inspection, or cutting. The latest point where fabric defects should be addressed is at assortment procedure. Fabric defects should not appear at final garments. Fabric defects can further be classified into 3 groups ●

color defects



construction defects



cleanliness

Workmanship defects Approved samples must always be referenced to see what is the approved workmanship. These defects should never be allowed to raise above a certain percentage.

Trims, accessories and embellishment defects These defects involve color and placement issues, as with workmanship defects, approved samples must always be referenced to for the correct placement and color.

Famous Textile Table QC defects list

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Defect Name: Holes.

Description: Visual:

How to identify: Broken holes in the fabric where you are able to see through the fabric to the other side.

How it happened: Holes can come from fabric or it could be caused by the production side, either by improper trimming or broken needle puncturing the fabric.

How to fix: Holes cannot be fixed, however very small holes might be able to be hand needled.

How to solve: Better inspection of fabric and cut piece. Ensure that fabric and cut pieces that are not up to standard are not put into line and production is wasted. Replace not standard cut pieces with usable ones before input.

Category: External holes are marked as critical, where as internal and non visible holes have to marked at as major.

Tolerance level: External holes are not tolerated and should be at 0%. Internal and non visible holes should never be more than at 3%.

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Defect Name: Misprints or off registration.

Description: Visual:

How to identify: The image that is printed is wrong and different from approved sample.

How it happened: Misprints can happen when the cut piece or fabric is not laid flat when printing or the screens that were used to print were not properly cleaned.

How to fix: Misprints cannot be fixed, however very small problems might be filled in with a needle and some pigment.

How to solve: Better inspection of fabric and cut piece. Ensure that fabric and cut pieces that are not up to standard are not put into line and production is wasted. Replace not standard cut pieces with usable ones before input.

Category: Misprints are marked as critical in visible areas, in non visible areas it is marked as major.

Tolerance level: Visible misprints are not tolerated and should be at 0%. Internal and non visible misprints should never be more than at 3%.

Famous Textile Table QC defects list

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Defect Name: Shading variations within products.

Description: Visual:

How to identify: Seams appear to be lighter or darker than the other seams surrounding it.

How it happened: Shading comes about from incorrect cutting or improper assortment.

How to fix: Depending on the seriousness of the shading, the percentage varies.

How to solve: Better inspection of fabric and cut piece. Ensure that fabric and cut pieces that are not up to standard are not put into line and production is wasted. Replace not standard cut pieces with usable ones before input. If the color shading is very serious, ensure that all cut pieces are tacked before input.

Category: Serious shading are marked as critical in visible areas, less serious it is marked as major.

Tolerance level: Serious shading is not tolerated and should be at 0%. Less serious should never be more than at 3%.

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Defect Name: Contaminated yarn / foreign yarn fly.

Description: Different colored yarn knitted into the fabric.

Visual:

How to identify: These defects can be identified by looking at the fabric area, they appear as different color on the fabric. They are especially noticeable on white to light colored fabrics.

How it happened: Defects come from fabric production stage.

How to fix: Small defects can be picked out using twizzers or a hand needle. When doing this ensure that fabric is not damages.

How to solve: Better inspection of fabric and cut piece. Ensure that fabric and cut pieces that are not up to standard are not put into line and production is wasted. Replace not standard cut pieces with usable ones before input.

Category: Visible defects are always marked as critical, where non visible defects are marked as minor.

Tolerance level: Visible defects cannot be tolerated and must be at 0%, where as non visible have a tolerance of 5%

Famous Textile Table QC defects list

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Defect Name: Grease/ Oil / dirty stains.

Description: Oil and dirt stains.

Visual:

How to identify: These defects can be identified by looking at the area, they usually appear as different colors. Oil stains are very easily identified when there is sufficient light.

How it happened: Oil stains generally come from sewing machines, machines such as over lock and flatlock machines are more prone to have oil stains. Occasionally oil stains can also come from fabric. This is especially true when dealing with spandex fabrics. Dirt stains are usually due to cleanliness of both the machine and the operator.

How to fix: Oil and dirt stains can be sprayed with stain remover and then brushed. All the residue powder must be brushed off to be considered as acceptable garments. Harder stains can be hand washed.

How to solve: Machine that is the culprit for the resulting oil stains must be found and adjusted. Ensure that the machine is no longer leaking oil. When changing color from a darker color to a lighter color, ensure that machines are properly cleaned before proceeding. Also make sure that handlers’ hands are properly cleaned when dealing with light colors.

Category: Dirt stains are always marked as critical, where as oil stains are marked as major.

Tolerance level: Dirt stains cannot be tolerated and must be at 0%, where as oil stains have a tolerance of 3%.

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Defect Name: Distorted knitting.

Description: Visual:

How to identify: Defect can be identified by looking at the fabric surface.

How it happened: These defects can be identified by looking at the surface area, they usually appear as irregular on the fabric.

How to fix: Defects come about at fabric production stage.

How to solve: Better inspection of fabric and cut piece. Ensure that fabric and cut pieces that are not up to standard are not put into line and production is wasted. Replace not standard cut pieces with usable ones before input.

Category: Misprints are marked as critical in visible areas, in non visible areas it is marked as major.

Tolerance level: Visible misprints are not tolerated and should be at 0%. Internal and non visible misprints should never be more than at 3%.

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Defect Name: Fabric lines due to knitting.

Description: Visible lines that affect the appearance of the fabric surface.

Visual:

How to identify: These defects can be identified by looking at the surface area, they usually appear as irregular on the fabric. Sometimes you might have to look at the fabric from side to side. They appear as from left to right or top to bottom defects.

How it happened: Defects come about at fabric production stage.

How to fix: These defects cannot be fixed and must be rejected if the defects appear in visible areas. In non visible areas, they are accepted up to a certain percentage.

How to solve: Better inspection of fabric and cut piece. Ensure that fabric and cut pieces that are not up to standard are not put into line and production is wasted. Replace not standard cut pieces with usable ones before input.

Category: Visible defects are always marked as critical, where non visible defects are marked as minor.

Tolerance level: Visible defects cannot be tolerated and must be at 0%, where as non visible have a tolerance of 3%.

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Defect Name: Needle damage.

Description: Visible small holes.

Visual:

How to identify: These defects can be identified by looking at the area surrounding stitches, they usually appear as tiny holes running along the fabric surface or as holes that are too big where the stitches are supposed to be. Broken needle puncture falls under holes and not this category.

How it happened: Defects generally come about either from using the wrong needle, or from fixing where the fabric holes from the previous stitch is still visible.

How to fix: These defects can be sprayed with a little thinner mixed with water and brushed before ironed to minimize the appearance of needle holes.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained or checked that the proper needle is used.

Category: Visible defects are always marked as critical, where non visible defects are marked as major.

Tolerance level: Visible defects cannot be tolerated and must be at 0%, where as non visible have a tolerance of 3%

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Defect Name: Open or broken seams.

Description: Portions of the garment that has not been covered with sewing thread.

Visual:

How to identify: These defects can be identified by looking at the area surrounding stitches, they usually appear as portions of the garment that are not sewn completely.

How it happened: Defects generally come about either from improper handling of the cut piece or machine.

How to fix: These defects must be returned into the sewing line for opening and fixing.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained.

Category: These defects are always marked as critical.

Tolerance level: Defects cannot be tolerated and must be at 0%.

Famous Textile Table QC defects list

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Defect Name: Seams twisted, puckered, spiraled or containing pleats.

Description: Visible small holes.

Visual:

How to identify: These defects can be identified by looking at the area surrounding stitches, they usually appear as irregular stitching along the seams. The approved sample must always be referenced to see what is acceptable.

How it happened: Defects generally come about either from improper handling of cut pieces or improper machine usage.

How to fix: These defects cannot be fixed and must be returned to sewing line to be open and fixed.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained.

Category: Visible defects are always marked as critical, where non visible defects are marked as major.

Tolerance level: Visible defects cannot be tolerated and must be at 0%, where as non visible have a tolerance of 3%.

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Defect Name: Part of garment caught in seams.

Description: Garment sewn into seams.

Visual:

How to identify: These defects can be identified by looking at the area surrounding stitches, they usually appear as incorrect stitching. The approved sample must always be referenced to see what is acceptable.

How it happened: Defects generally come about either from improper handling of cut pieces.

How to fix: These defects cannot be fixed and must be returned to sewing line to be open and fixed.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained.

Category: Visible defects are always marked as critical.

Tolerance level: Visible defects cannot be tolerated and must be at 0%.

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Defect Name: Broken stitch.

Description: Non continuous sewing thread.

Visual:

How to identify: These defects can be identified by looking at the sewing thread. Any sewing thread that is exposed or not continuous is identified as broken stitch. Generally broken stitch can appear anywhere on the garment and particularly at hems, cuffs and neck areas.

How it happened: Defects generally come about from improper trimming or improper machine usage.

How to fix: Garments should be returned back to sewing line for open and fixing. However smaller defects might be hand needled.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained in the proper usage of the machine as well as the proper way to trim excess thread. In the case where the machine and not the operator is at fault, machine must be readjusted before production is allowed to continue at the particular station.

Category: Visible defects are always marked as critical.

Tolerance level: Visible defects cannot be tolerated and must be at 0%.

Famous Textile Table QC defects list

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Defect Name: Skipped or dropped stitches.

Description: Irregular stitching.

Visual:

How to identify: These defects can be identified by looking at the area surrounding stitches, they usually appear as irregular stitching along the seams. The approved sample must always be referenced to see what is acceptable.

How it happened: Defects generally come about either from improper handling of cut pieces or improper machine usage.

How to fix: These defects cannot be fixed and must be returned to sewing line to be open and fixed.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained in the proper usage of the machine as well as the proper way to trim excess thread. In the case where the machine and not the operator is at fault, machine must be readjusted before production is allowed to continue at the particular station.

Category: Visible defects are always marked as critical, where non visible defects are marked as major.

Tolerance level: Visible defects cannot be tolerated and must be at 0%, where as non visible have a tolerance of 3%.

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Defect Name: Uncovered seams, edges, cuffs and hems.

Description: Edges of the garment that have been covered with sewing thread but still showing edges.

Visual:

How to identify: These defects can be identified by looking at the such as edges, seams, cuffs and hems, they usually appear as edges of the garment that are still showing raw fabric.

How it happened: Defects generally come about either from improper handling of the cut piece or machine.

How to fix: These defects can be trimmed using trimmers.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained in the proper usage of the machine. In the case where the machine and not the operator is at fault, machine must be readjusted before production is allowed to continue at the particular station.

Category: These defects are always marked as major.

Tolerance level: Defects can tolerated up to 3%.

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Defect Name: Operation missing or incomplete.

Description: Incomplete garment.

Visual:

How to identify: These defects can be identified by looking at the garment. Garment is not complete as per the approved sample.

How it happened: Defects come about from improper handling of cut pieces.

How to fix: Garments should be returned back to sewing line for completion.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must complete all cut pieces in the bundle. Line leaders should look at proper placement of before and after cut pieces. If the garment was not sewn intentionally, the operator will face disciplinary action with management.

Category: Visible defects are always marked as critical.

Tolerance level: Defects have a tolerance of 0%.

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Defect Name: Pockets mis-positioned or misaligned.

Description: Pocket not in correct position.

Visual:

How to identify: These defects can be identified by looking at the pockets. Approved sample must be referenced for the correct position of the pockets.

How it happened: Defects come about from improper placement of pockets.

How to fix: Garments should be returned back to sewing line for open and fixing.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must be retrained. Line leaders should look at proper placement of pockets, as well as provide better visual guides.

Category: Visible defects are always marked as critical.

Tolerance level: Defects have a tolerance of 0%.

Famous Textile Table QC defects list

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Defect Name: Neck shape.

Description: Shape of the neck is not as per approved sample.

Visual:

How to identify: These defects can be identified by looking at the neck of garment tops. Usually the two sides are not symmetrical or the neck is either too wide or too narrow.

How it happened: Defects come about either from improper handling of the cut piece or machine. However these defects can also be caused by defective cut pieces.

How to fix: Garments should be returned back to sewing line for open and fixing. However smaller defects might be sent to ironing to see if its possible to iron the neck to the correct shape.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained in the proper usage of the machine. In the case where the cut piece and not the operator is at fault, assortment and proper cut piece inspection must be followed.

Category: These defects are always marked as major.

Tolerance level: Defects can tolerated up to 3%.

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Defect Name: Sewing thread not matching.

Description: Color of the sewing thread does not match the rest of the garment.

Visual:

How to identify: These defects can be identified by looking at the sewing thread used in one area with sewing thread used in another area. They generally appear to be significantly lighter or darker or even totally different color.

How it happened: Defects generally come about either from poor planing of use of sewing thread or sewing thread wastage.

How to fix: If the difference in color is only slight, they can be accepted for shipment. However complete color difference cannot be accepted and must be sent back into sewing to open and fix.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained in the proper usage of the machine so as not to waste sewing thread. Proper consumption must be followed. Ensure that sewing thread is not wasted and if replacement sewing thread is to be used, they are used to sew complete garments.

Category: These defects are always marked as major.

Tolerance level: Defects can tolerated up to 3%. In the case where the defect is in non visible areas it is marked as minor and tolerated up to 5%.

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Defect Name: Seams not aligned at crossing of seams.

Description: Seams are not lined up at intersection of seams.

Visual:

How to identify: These defects can be identified by looking at areas like armpit and crotch. These defects appear as seams not forming a cross or T.

How it happened: Defects generally come about either from improper handling of the cut piece.

How to fix: These defects must be returned to production to be open and fixed.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained in the proper usage of the machine.

Category: These defects are always marked as major.

Tolerance level: Defects can tolerated up to 3%.

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Defect Name: Stripes not matching.

Description: Up and down or non symmetrical stripes on yarn dyed garments.

Visual:

How to identify: These defects can be identified by seams and the sleeves of the garment. Sleeve should be paired and stripes must match at side seams.

How it happened: Defects come about from improper handling of cut pieces.

How to fix: Garments should be returned back to sewing line for open and fixing.

How to solve: Better inspection of fabric and cut piece. Ensure that fabric and cut pieces that are not up to standard are not put into line and production is wasted. Replace not standard cut pieces with usable ones before input. If the color shading is very serious, ensure that all cut pieces are tacked before input..

Category: Any mismatch stripe that is more than 50% of the stripe or ½ inch has to be marked as critical. Any mismatch or non paring stripe that is less than 50% of the stripe or ½ inch is marked as major.

Tolerance level: Critical defects have a tolerance of 0%. Major defects have a tolerance of 3%.

Famous Textile Table QC defects list

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Defect Name: Misplaced label.

Description: Labels that have been placed in the wrong position or slanted vertically or horizontally.

Visual:

How to identify: These defects can be identified by looking at the main, care and size labels. If they are not in the correct position as per the approved samples, then they will be considered as defects. Off center labels can be easily identified by folding the garments in half from top to bottom, label should appear to be halved by the fold.

How it happened: Defects come about from improper placement of labels when sewing.

How to fix: These defects must be returned to the sewing line to be open and fixed.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained on the proper placement of labels before sewing.

Category: These defects are always marked as minor.

Tolerance level: Defects can tolerated up to 5%.

Famous Textile Table QC defects list

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Defect Name: Damage or illegible label.

Description: Labels that have been damaged or illegible.

Visual:

How to identify: These defects can be identified by looking at the main, care and size labels. If they cannot be read or are not sewn correctly, they are considered as defects.

How it happened: Defects from heat seal labels come about from incorrect temperature or pressure or a defective heat seal label. For sewn labels, defects come about from improper trimming or improper machine usage.

How to fix: Heal seal labels can be removed with thinner and water and gently brushed off, they must be returned back into the line for fixing. Sewn label defects must be returned to the sewing line to be open and fixed.

How to solve: When these defects starts to appear at close to 2% or 5 pieces, the production must be informed and the operator must must re-trained.

Category: These defects are always marked as major.

Tolerance level: Defects can tolerated up to 3%.

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