01QUALITY•Ideal condition of excellence.•Product quality is based on a product attribute. •User-based quality is fitness for use, • manufacturing based quality is conformance to requirements, •value based quality is the degree of excellence at an acceptable priceISO 9000:2000 Defines it as “degree to which a set of inherentcharacteristics fulfill requirement.”
02Quality inspection in apparel industries:“Visual examination or review of raw materials, partially finishedcomponents of garments and completely finished garments inrelation to some standards, specifications, or requirements, aswell as measuring garments to check if they meet the requiredmeasurements.”
03Quality inspection in apparel industries:•done to control quality of garments. •Checking of fabric, •sewing thread, •button, •stitch, • zipper, •garments size etc according to required standard or specification is known as inspection.•Quality inspection is important for every section of apparelindustries.
04Steps in apparel industries to control quality1. Raw Material Inspection;2. In Process Inspection;3. Final Inspection;
05Raw Material Inspection:•Fabric Inspection•Sewing Thread Inspection•Trims & Accessories check
06Fabric Inspection• done through Fabric Inspection machine.• very important for every industries .• In fabric inspection their checks several things i.e. in fabric are there any defect available or not. In fabric, fabric defects viz. off shade or shade variation, hole in fabric, barre effect etc. can be visual after entering into the store room. For those defects it will be problem able for making garments making.• In fabric inspection, also check fabric strength, color, quantity To check fabric there are different system i.e. 4 point system, 10 point system etc.
10Sewing Thread InspectionDuring stitching fabric frequently brakeage of sewing threadis one of the great problems for garments manufacturing. Sothat it is necessary to check •thread construction, •sewability, •color, •imperfection, • finish, package •density, •winding, •yardage of sewing thread.
11Sewing Thread Inspection•In thread construction •thread number, •thread ply, •thread tenacity, •thread elongation, •number of twistis necessary to check.
12Trims & Accessories check•Button,•Zippers• interlining,• label &•tagsalso need to check so that quality can be maintain accordingto required quality.•For button, •button strength, • button color, • quantity etc are checked.
13In Process Inspection• Inspecting different parts of garments before sewing are called in process inspection.• It starts from marker making, than fabric spreading, fabric cutting, fabric sewing, pressing or finishing checking is done in process. – marker making – fabric spreading – fabric cutting – sorting/ bundling – fabric sewing – seam defects – assembly defects – pressing/ finishing defects
14Marking inspectionFactors which must be checked• It is necessary to check all the parts of garments pattern are in marker.• In marker labelling or coding of pattern should be checked• Pattern direction should be checked.• The entire pattern are sated correctly.• Pattern grain line is very important thing which must be considered during marker making.• During marker making every pattern pieces dimension should be accurate.• During marker making fabric length and width should be considered.• Marker width• Notches & drill marks• Knife clearance• Checks and stripes (mittering)
Pattern Grading Defects1. Grade Not Conforming to Specification measurements Finished product not measuring to specified dimension and component parts not fitting in relationship to notches, openings and seams such as armholes sleeve heads neck bands, neck openings and side seams inseams, waist measurements and etc.2. Distorted Grading: Unbalanced patterns which would cause twisted seams, puckering, pleating and a general uneconomical yardage waste.
Marking defects1.Shaded Parts:- All component pans not included in same section.2. Pieces not Symmetrical:-Will not sew together without puckering or pleating.3. Not Marked by Directional Lines:-Bias will not lit together, causing twisting, puckering. pleating and a general mismatching of component parts.4. Skimpy marking:-Marker did not use outside perimeter of pattern.Pattern moved after partially marked to fit into space.5. Notches and Punch Marks:-Left out., not clearly marked or misplaced.6. Marker Too Wide:-Parts will not catch in lay, causing skimpy garments or requiring results.7 Marker Too Narrow:-Results In wasted material.8. Mismatched Plaids-Marker did not block component parts to match.9. Misdirected Napping:-Patterns not marked in same direction and napped fabrics.
17Spreading inspectionFactors which must be checked• Fabric Nature• Ply alignment• Ply tension/slackness• Bowing• Splicing• Grain-line• Shade variation• Selvedge alignment & tightness• Fabric width• Checks• Static electricity
Spreading Defects1. Uneven Spreading:- Front edge of lay is not even, resulting in front or back edge of marker not catching all ply.2·. Narrow Material:- Bolts or rolls of material too narrow to cover marker width.3. Missed Sectional Breaks:- Sectional marker breaks too long or too short. Parts in lay will be short or material wasted.4. Improper Tension:- Cloth spread too tight or too loose, causing parts not to fit in sewing or distorting dimensions of garments.5. Mismatching Plaids:- Material spread too loose or too tight causing plaid lines to run diagonally or bow.6. Misdirected Napping:- Air pockets not removed. Napped material reversed in spreading.7. Improper Matching of Face of Material:-Not spread face down, face up or face to face as required.
19Cutting inspectionFactors/defects which must be checked• Frayed edge• Fuzzy, ragged or serrated edges• Ply to ply fusion• Single edge fusion• Pattern precision• Notches & drillers• Cutting Equipment precision
Cutting Defects1.Marker or Perforator:- Not stapled or stencilled on lay to catch both edges causing parts to miss in cutting. Too tight or too loose, distorting dimensions of garment. Perforated stencil ,not powdered or inked, sufficiently to show distinct lines, notches and punch marks.2. Misplaced Piece Rate Tickets or Bundle Members:-Attached to, or marked on, wrong bundles, causing mixed sizes or land shades.3. Drill Marks:- Drill marks misplaced, not perpendicular, omitted or wrong side drill used.4. Opening Slits:- Cut under above to the side or at incorrect angle. Not cut through entire bundle or omitted.5. Improper Cutting:- Not following marker lines, resulting in distorted parts. Letting knife lean causing top and bottom ply to be of different sizes.6. Notches:- Misplaced, too deep, too shallow or omitted.7. Oil Spots:- Equipment improperly oiled or cleaned.8. Improper Knife Sharpening:-Causing ragged, frayed or fused edges on bundles.9. Knife or Scissor Cut:-Piece damaged by over run in cutting previous piece.
21Sorting/ Bundling inspection• It is necessary to check numbering, sorting, and bundling is done accurately.Defects.1. Not Stacked in Numerical Order: Bundle numbers not inorder on rack skid or box.2. Matching Linings: Wrong size or wrong material.
22Sewing inspection• Most large & important section.• Necessary to check all the machine operators work.• Some common faults and problems must be considered – Sewing defects – Seaming defects – Assembly defects – Pressing or Finishing defects
24Stitching Defect CauseSewing inspectionMachine do not run Not plugged in or turned on Outlet switch off. Circuit breakdown.Machine do not stitch properly Machine dirty. Machine incorrectly threaded Needle needs replacement.Machine does not feed Insufficient or too muchproperly pressure on pressure foot Stitch length too short.
25Stitching Defect CauseSkipSewing inspection stitching Machine incorrectly threaded. Machine dirty Needle damage/needle set or threaded incorrectly. Needle makes hole too large or too short Needle too much fine for thread Thread tension too tight/ thread stretches when heated. Machine timing needs adjustment Fabric not held properly.
27Stitching Defect Sewing inspection CauseSkip stitching (overedge Loopers are incorrectly set.machines) Needle to looper relation incorrect. Wrong type thread.Skip stitching (blindstitch Stitch-depth too shallow.machines)Wavy seams Stitch length too short. Pressure too heavy or lightWavy seams (overedge machine) Differential feed needs increasing
28Stitching Defect Causepuckering inspectionLight weight fabric, wash & wear, tightly woven. Sewing Seam on straight grain. Fabric not held properly. Thread tension too tight. Needle needs replacing. Thread wrong size for needle/ threads are different on bobbin & needle. Too heavy pressure on foot. Wrong stitch length. Wrong seam class choice for material.Puckering (overedge Differential feed needs to be reduced.machines)
29Stitching Defect Cause Sewing inspectionPressure on foot incorrect.Plies feed unevenly Plies lock or stitch together. Pressure foot sticks to material. Garment sections are of different length. Garment sections are cut on different grains. Feed dog at incorrect height or badly worn. Inappropriate pressure-foot. Inappropriate needle plate. Operator not feeding upper layer properly. Wrong machine- use a needle-feed machine if available.
30Stitching CauseDefect Sewing inspectionUnbalanced Different thread on needle & bobbin.tension Thread slipped out of tension disc. Thread not feeding off cone or spool properly Machine dirty. Machine incorrectly threaded Needle needs replacement/ set incorrectly Poor quality of thread (too dry, coarse, fine etc). Thread catches on rough surfaces of thread guide, throat plate or thread spindle. Bent, rusted, or incorrect bobbin/ improperly or unevenly wound bobbin/ bobbin has several layers of thread/bobbin thread out/ bobbin case screw has worked out.
31Stitching Defect Cause Sewing inspectionUnbalanced tension Looper tension needs adjustment(overedge machine)Uneven stitches Thread does not feed smoothly/ thread has wrong twist/ thread incorrectly threaded between tension discs. Pressure too light. Burns or rough spots along the path of thread. Operator not feeding properly
32Stitching Defect CauseSewing inspectionCracked seam Machine dirty. Lint between the tension discs, guides or eyelets Bobbin or looper thread tension too tight. Needle too small or wrong point. Inappropriate stitch length for material. Too tight tension. Thread not moving smoothly through guides or eyelets. Thread too large or machine has rough spots or burns.Cracked seam Looper thread tension too tight.(overedgemachine)
33Stitching Defect CauseThread Sewing inspection breakage Poor quality thread/ wrong size of thread. Tension too tight. Needle set improperly. Machine dirty. Machine incorrectly threaded Needle needs replacement. Pressure bar not down. Take-up lever not in raised position at the beginning of stitch. Burns on needle eye, throat plate, guides or thread spindle. Operator pulling fabric during tension/ did not release tension before removal of material.
34Stitching Defect Cause Sewing inspectionThread breakage Needle & looper need adjustment(overedge machine)Seam grin Stitch bight too narrow. Stitch length too short. Thread not set into tension discs properly Tension on needle thread too loose.Seam grin (overlock Wrong stitch typemachine) Tension needs adjustment.
35Stitching CauseSewing inspectionDefectMachine jam Machine dirty. Machine incorrectly threaded Needle set incorrectly or damaged. Static electricity pulls fabric into needle hole Pressure bar not down. Needle plate hole too large. Threads not held at beginning. Bobbin inserted incorrectly. Pressure foot wrong type and not holding fabric firmly.
36Stitching Defect CauseUnthreading inspection Sewing of Thread end too short.needle Take-up lever not in its highest position. Thread ends not held at beginning of stitch Operator did not chainstitch.Overedge Knives blunt.machine ragged Knives incorrectly set.edges, trimmed Wrong choice of thread for fabricedges areunevenMachine noisy Machine dirty Damaged machine. Needle dull, bent or set incorrectly
37Stitching Defect Sewing inspection CauseNeedle breakage Needle needs replacement/ set incorrectly. Pressure foot too loose. Bobbin or bobbin-case incorrectly set. Operator stitching over pins or zippers. Operator pulling fabric while stitching or without raising pressure foot. Upper tension too tight. Incorrect size of needle or thread for material. Fabric too thick.Needle breakage Needle hitting looper.(overedge machine)
38Stitching Defect Cause Sewing inspection Machine dirty.Bobbin threadbreakage (lockstitch Improperly threaded machine.machine) Bobbin or bobbin-case incorrectly set. Bobbin tension too tight. Bobbin too full. Thread unevenly wound on bobbin Bobbin screw worked out and catching the thread. Spring on bobbin-case worn to a sharp groove. Burns on throat plate or rotary hook. Bobbin pigtail caught in bobbin-case
39Pressing Defect CauseIron does not heat. Iron not plugged in or turned on. Boiler not turned on. Circuit breaker or outlet off. Temperature control set too lowIron spits Iron did not heat completely before use. Temperature control set too low. Steam control malfunctioned.
40Sewing inspectionSeaming defects:• Uneven width• Fault stitch line• Back stitch must be given properly• Twisting• Check or strip matching• Seam matching• Wrong stitch face side or back side;• Thread color shade variation.
Restitched Seams / Broken Stitches MINIMIZING THREAD Excessive Restitched Seams BREAKAGE: 1) Use a better quality sewing thread. This may include going to a higher performance thread designed to minimize sewing interruptions. (See the Thread Selection Guide and/or Minimizing Thread Breakage & Skipped Stitches); 2) Insure proper machine maintenance and sewing machine adjustments;DESCRIPTION: Where a "splice" 3) Make sure sewing machines areoccurs on the stitch line. If this occurs properly maintained and adjustedon Topstitching, then the seam does not for the fabric and sewing operation.appear to be 1st quality merchandise. (See Machine MaintenanceCaused by 1) thread breaks or thread Checklist.);run-out during sewing; or 2) cut or broken 4) Observe sewing operators forstitches during a subsequent treatment of correct material handlingthe finished product (i.e., stone washing). techniques.
•Open Seam - Seam Failure - Stitch MINIMIZING SEAM FAILURES - STITCH: 1) Use a better quality sewing thread. This may include going to a higher• DESCRIPTION: Where the performance thread designed to give threads in the seam have greater seam performance. (See the ruptured leaving a hole in the stitch Thread Selection Guide.); line. 2) Use the proper size thread for theCaused by application; 3) For knit fabrics, check for "Stitch• 1) Improper stitch for application; Cracking". Stitch Cracking can be• 2)Inadequate thread strength for caused by any of the following: not seam; enough stitches per inch; improper seam• 3) Not enough stitches per inch. width or needle spacing for application; improper stitch balance; and improper thread selection.
Open Seam - Seam Failure - Fabric Bartacks Used to Reinforce Fly Seam MINIMIZING SEAM FAILURES - FABRIC: 1)Reinforce stress points with Bartacks. Make sure the bartacks are• DESCRIPTION: the proper length and width for the Where the stitch application; line is still intact but 2) Check to make sure the patterns the yarns in the fabric have been designed for proper fit; have ruptured. 3) Make sure the ideal seam construction is being used; 4) Contact your fabric supplier.
Seam Failure - Seam Slippage Seam Slippage on Rayon Fabric MINIMIZING SEAM FAILURES –• DESCRIPTION: Where the yarns SEAM SLIPPAGE: in the fabric pull out of the seam 1) Consider changing the seam from the edge. This often occurs on construction to a French seam fabrics constructed of continuous construction; filament yarns that are very smooth 2)Increase the seam width or width and have a slick surface. Also of bite; caused by loosely constructed 3)Optimize the stitches per inch; 4) fabrics. Contact your fabric supplier.
Needle Cutting on Knits MINIMIZING NEEDLE CUTTING ON KNITS: 1)Make sure the proper thread size and needle type and size are being used for the fabric• DESCRIPTION: Where needle holes 2) Make sure the fabric has appear along the stitch line that will been properly stored to prevent eventually turn into a "run". Generally drying out and has been finished caused by the needle damaging the properly; fabric as it is penetrating the seam. 3) Check with your fabric manufacturer.
•Excessive Seam Puckering - WovensDESCRIPTION: Where the seam does not lay flat and smooth along the stitchline.Caused by one of the following:1) Feed Puckering - where the plies of fabric in the seam are not being aligned properly during sewing;2) Tension Puckering - where the thread has been stretched and sewn into the seam. The thread then causes the seam to draw back and pucker;3) Yarn Displacement or structural jamming - caused by sewing seams with too large of thread that causes the yarns in the seam to be displaced, giving a puckered appearance.
MINIMIZING EXCESSIVE SEAM PUCKERING:1)Use the correct thread type and size for the fabric. In many cases, a smaller, higher tenacity thread is required to minimize seam puckering but maintain seam strength2) Sew with minimum sewing tension to get a balanced stitch;3) Make sure machines are set up properly for the fabric being sewn;4) Check for proper operator handling techniques.
•Puckered Seams -Knits & StretchWoven SOLUTIONS: 1) If sewing machines are equipped with differential feed, set them properly for the fabric; 2) Use minimum presser foot pressure during sewing; and 3) Observe operator for correct handlingDESCRIPTION: Where techniques. Too much stretching of the fabricthe seam does not lay by the sewing operator will cause thisflat after stitching. problem.
•Excessive Seam GrinDESCRIPTION: Where thestitch balance is not properlyadjusted (stitch too loose) and SOLUTIONS: To correct, readjust theyou can see the seam opening sewing machine thread tensions so thatup. To check for Seam Grin, the proper stitch balance is achieved.apply normal seam stress across Too much tension will cause otherthe seam and then remove the problems including seam failures ("Stitchstress. If the seam remains Cracking"), excessive thread breakage,opened, then the seam has too and skipped stitches.much "grin through".
•Improper Stitch Balance - 301 Lockstitch SOLUTIONS: 1) Use a quality thread with Consistent frictional characteristics; 2) Properly balance the stitch so that the needle and bobbin threads meet in the middle ofDESCRIPTION: Where loops the seam. Always start byare seen either on the checking the bobbin threadbottomside or topside of the tension to make sure it is setseam. This is particularly correctly, so that the minimumevident with different colored thread tension is required to getneedle and bobbin threads. a balanced stitch.Also, where the stitch is tooloose.
•Improper Stitch Balance - 401 ChainstitchDESCRIPTION: Where SOLUTIONS:the loops on the 1) Use a quality thread with consistent frictional characteristics;bottomside of the seam are 2) Properly balance the stitch so thatinconsistent and do not when the looper thread isappear uniform. unraveled, the needle loop lays over half way to the next needle loop on the underside of the seam
•Improper StitchBalance - 504Overedge Stitch SOLUTIONS:DESCRIPTION: Where the 1) Use a quality thread with consistentneedle loop is not pulled up frictional characteristicsto the underside of the seam 2) Properly balance the stitch so that when theand the"purl" is not on the looper thread is unraveled, the needle loopedge of the seam. lays over half way to the next needle loop on the underside of the seam.
•Ragged/Inconsistent Edge - Overedge OrSafety stitch SeamsDESCRIPTION: Where the edgeof the seam is either extremely"ragged" or "rolls" inside the stitch.SOLUTIONS: 1) Make sure the sewing machineknives are sharpened and changedoften; 2) The knives should be adjustedproperly in relationship to the "stitchtongue" on the needle plate to obtainthe proper seam width or width bite.In the photo, the trimming kniveshave been set wider than the "stitchtongue" on the needle plate causingthe "ropy" appearance.
56Sewing inspectionAssembly defects:• Finished component of not accurate size.• Garments not accurate in size.• If any design skip to join.• Component is not joining in right place.• If lining is tight or loose.• If parts direction is wrong.
57Sewing inspectionPressing or Finishing:• Fabric burn or burn spot attach with body.• Any types of water spot.• Color shading occurs because of hot ironing.• Button is insecure or broken.• Garments are folding accurately.• Pocket is pressed smoothly and except fold.• Garments shape is accurate.“Stains, Wrinkles, Correct labels, Any thing that detracts fromoverall appearance”
58Sewing inspectionFolding defects• garment is not folded to specification• garment not folded with proper material like cardboard, tissues or other material.• incorrect pins or folds• garment not buttoned• label not showing
59Final Inspection• In final inspection generally inspect fully complete garments. Before final inspection there has no chance to check complete garments. It is important from the buyer to finally check. In final inspection normally garments size, form fitting, fabric faults are check.
60DEFECT ZONES• A zone- the defects of the garment which is visible when it is packed.• B zone- the defects of the garment which is visible when garment is opened flat.• C zone- the defects which can be seen when the garment is turned. – A defect in “A” zone is considered more serious than a defect in “B” zone – A defect in “B” zone is considered more serious than a defect in “C” zone and will be categorised accordingly. Critical defects list
61Garment No-01 (Shirt)
Shirt inspection check list 63 No Location Inspect for 01 Collar Both points are same or not, strip or check is match accurately, stitch, collar flat or not. 02 Size Size label is in correct place, and every parts size is correct or not. 03 Button & button Placed in right place or not, evenness of gap between one button to hole other, stitch is done correctly, are there any broken button or not. 04 Pocket Pocket upper edge horizontal or not, pocket position, size, stitch, stripe or check is match, flat or not. 05 Hem Stitch, are there any puckering occur or not, edge free from stitch. 06 Yoke & shoulder Stitch, puckering problem, skipped stitch. 07 Side seam Pattern matching, stitch, free from raw edge. 08 Cuffs Strips or check matching, top stitch, flat or not. 09 Finished Threads edge comes out or not, are there any oil spot or not, fabric appearance fault, color matching, strip matching.
Causes & Remedies 64Location Defects Causes RemediesCollar Both points are not aligned. Pattern mistake Proper pattern marking strip or check is not match Pattern mistake Proper mitering accurately/stitch collar flat or not Improper Stitch/seam Proper folding & stitchingSize Incorrect size parts Improper ticketing & Proper ticketing & bundling bundlingButton & Not placed in right place Improper marking Proper markingbutton hole unevenness of gap between Improper measuring & Proper marking one button to other marking stitch is done correctly/ extra Improper stitching/ Proper setting of thread machine settings machines broken button Improper inspection ReplaceSleeve Unequal size Improper Proper measurement, measurement/stitching marking, & stitch.
Location Defects Causes RemediesPocket Improper positioning & stitch Improper marking/stitch Proper marking & stitchHem puckering, raw edge. Improper machine Proper settings, fabric settings/ fabric type & stitch type/stitchYoke & Stitch, puckering problem, Machine setting/ Proper machineshoulder skipped stitch. workmanship setting & workmanshipSide seam Improper pattern matching, Improper pattern/stitch Proper marking & stitch, raw edge stitch (by aligning edges)Cuffs Strips or check not matching Improper marking. Proper marking Improper top stitch, not flat Slippage of back side or Folders may be used improper stitchFinished Extra threads edge Floatation on seam Cut it.appearance strip matching Improper Spread & mark spreading/marking properly fabric fault Improper fabric Splicing or other fault Inspection etc. recovery processes Shade variation Improper spreading Shade sorting during spreading
Inspection of Sample (Shirt) 66A zone Defects1.CollarDefects Causes Remediesuneven (edges are Improper marking Marking should be accuratenot on a straight Operator’s fault with proper techniques ofhorizontal line) stitching Cutting faults Appropriate equipmentsUnequal Improper marking Proper marking with skilleddimensions stitching. Overstretched fabric Accurate tension over fabric
Inspection of Sample (Shirt) 67A zone Defects2. Front placketDefects Causes Remediesbaggy (fullness) at Improper marking Marking should be accurate(incollar. Operator’s fault terms of measurement & relative positioning of button & Button holes are not buttonholes) with proper according to button techniques of stitching placement
Inspection of Sample (Shirt) 68 A zone Defects 3. LabelsDefects Causes RemediesNot placed at (with Improper marking Marking should be accurate(inthe reference of Operator’s fault terms of measurement & relativecentre back) positioning of labels & tags) with proper techniques of stitching
Inspection of Sample (Shirt) 65A zone Defects4. PocketDefects Causes RemediesMitering defects Improper marking Marking should be accurate Operator’s fault with proper techniques of stitching. Cutting faults Appropriate equipmentsExtra thread Improper inspection Proper inspection & extra thread should be trimmed. Floated on seam Appropriate equipments should be used to avoid this.
Inspection of Sample (Shirt) 70A zone Defects5. Button holesDefects Causes RemediesExtra thread Improper inspection Inspection should be proper. Floated on the seam Appropriate equipments should be used to avoid this.Improper stitch Inaccurate setting of Machine setting should be machine accurate. Wrong type of thread Thread should be inspected in terms of tenacity, count, ply, twist etc.
Inspection of Sample (Shirt) 71B zone Defects
Inspection of Sample (Shirt) 72 B zone Defects 1. ArmholeDefects Causes RemediesMisaligned Improper pattern Pattern should be accurately developedseam making & marking with accurate marking. Operators fault Should be aligned with skilled stitching.Improper stitch Operators fault Should be done with proper(not uniformly workmanship.distant witharmhole seam)
Inspection of Sample (Shirt) 73 B zone Defects 2. YokeDefects Causes RemediesMitering defect Improper marking Marking should be accurate.
Inspection of Sample (Shirt) 74B zone Defects3. Side seamDefects Causes RemediesMitering defect Improper marking Marking should be accurate.
Inspection of Sample (Shirt) 75 C zone Defects 1. Armhole seamDefects Causes RemediesRaw edge Operator’s fault. Stitching should be proper. Folders/templates may be used.Roping Pattern-making & Patterns should be accurately(puckering) marking defect developed with proper marking. Stitching defect Should be done with proper skill & (operator’s fault-applying workman ship too much tension) Machine fault Properly check the settings of machine & its components.
Inspection of Sample (Shirt) 76 C zone Defects 2. Side seam slitDefects Causes RemediesRaw edge Operator’s fault. Stitching should be proper. 3. Sleeve placketDefects Causes RemediesRaw edge Operator’s fault. Stitching should be proper.
Inspection of Sample (Shirt) 77C zone Defects4. Cuff seamDefects Causes RemediesTop stitch not Operator’s fault. Stitching should be proper.covering the Slippage of fabric Folders/templates may be used.back fabric of during top stitch.cuff seam
Analysis of garment 1 as per cutting room defects: 78shade variation noPieces not symmetrical noMisdirected napping -Improper tension while nospreadingUneven spreading noMisplacement of marker yeswhile cuttingImproper cutting noImproper knife sharpening -Improper drill and notch -marksIncorrect size cutting no
Analysis of garment 1 as per sewing room defects:Needle damage noSkipped stitch yesThread break yesSeam pucker yesWrong stitch density noUneven stitch noOil spots or stains noLoose thread yesOpen seam yesRun off yesImproper thread tension yesBroken stitch yesNotch exposed no
Omission of any part of garment yesTwisted seam yesPieces not aligned yesReverse pieces noExcessive fullness noUneven edge yesRagged edge yesHole noMisplaced components yesMisaligned seam yes
Analysis of garment 1 as per finishing room defects:Thread not trimmed yesSeam tear yesInadequate pressing noGarment not properly dried -Pressing producing shine in fabric noLabels not showing noCuts or nicks no
Garment No -02 (Knitted T-Shirt)Location Inspect for RemediesCollar Both points are same or not, accurately Proper marking, stitching stitch, collar flat or not.Size Size label is in correct place, and every Proper labeling & bundling parts size is correct or notButton & Placed in right place or not, evenness of Proper marking(measurement) & skilledbutton hole gap between one button to other, stitch is stitching done correctly, are there any broken button or notPocket Pocket upper edge horizontal or not, pocket Proper marking for placement & skilled stitch position, size, stitch, stripe or check is match, flat or not.Hem Stitch, are there any puckering occur or not, Proper tension & skill during stitch edge free from stitch.shoulder Stitch, puckering problem, skipped stitch Proper skill stitching& use of mobilon tape (proper over-lock).Side seam Pattern matching, stitch, free from raw edge Avoid excess tension(force) with skilled workmanship.Sleeve hem Proper over-lock. Proper machine settings & skilled stitchingFinished Threads edge comes out or not, are there Can be avoided during inspection.appearance any oil spot or not, fabric fault, color matching, strip matching.
Garment no-02 (Knitted T-Shirt) 83A zone Defects1. Front placketDefects Cause Remediesgathering/ Fabric stretched during Set the machinelooseness at stitching (too much accurately accordingplacket pressure at foot) the knitted fabric & stitch properly
Garment no-02 (Knitted T-Shirt) 84A zone Defects2. CollarDefects Cause RemediesImproper top Fabric stretched during Set the machinestitch stitching (too much pressure accurately according the at foot) knitted fabric & stitch properly due to lack of proper stitching Align the seam properly (operator’s fault) & stitch with skilled workmanship
Garment no-02 (Knitted T-Shirt) 85B zone Defects1. ArmholeDefects Cause RemediesNot aligned Fabric stretched during Set the machineproperly stitching (too much pressure accurately according the at foot) knitted fabric & stitch properly due to lack of proper by proper marking & marking/ proper stitching aligning the seam accurately before stitch
Garment no-02 (Knitted T-Shirt) 86C zone Defects1.Front placketDefects Cause RemediesRaw edges Operator’s fault. Properly inspect the garment & Finish the edges with overlock machines Improper inspection
Garment no-02 (Knitted T-Shirt) 87C zone Defects2. HemDefects Cause RemediesRaw edges Operator’s fault. Properly inspect the garment & Finish the edges with overlock machines Improper inspection
Garment no-02 (Knitted T-Shirt) 88C zone Defects3. Collar edgesDefects Cause RemediesRaw edges (edges Operator’s fault. Properly inspect thenot finished properly) garment & Finish the edges with overlock machines Improper inspection
Analysis of garment 2 as per cutting room defects: 89shade variation noPieces not symmetrical noMisdirected napping noImproper tension while slightspreadingUneven spreading noMisplacement of marker nowhile cuttingImproper knife sharpening noImproper drill and notch nomarksIncorrect size cutting no
Analysis of garment 2 as per sewing room defects:Needle damage noSkipped stitch noThread break noSeam pucker yesWrong stitch density noUneven stitch noOil spots or stains noLoose thread noOpen seam noRun off noImproper thread tension noBroken stitch noNotch exposed no
Omission of any part of garment Yes (half moon patch)Twisted seam noPieces not aligned yesReverse pieces noExcessive fullness noUneven edge yesRagged edge yesHole noMisplaced components noMisaligned seam yes
Analysis of garment 2 as per finishing room defects:Thread not trimmed yesSeam tear noInadequate pressing -Garment not properly dried -Pressing producing shine in fabric -Incorrect pins or folds in garment -Labels not showing noCuts or nicks no