Garments defect classification with root cause

1. Presentation on Defect Classification List and
Training Program.
Organized By: Quality Management System(QMS).
Trainer : Abdul Hannan.
Designation: QMS Executive .

3. Methods
Man
Machine
Material

4. 1. Critical Defect.
2. Major Defect.
3. Minor Defect.

5.  Goods that do not comply with Requirements for babies and
children’s wear.
 Goods that do not comply with Chemical Restrictions.
 Cartons found with Insects, strong odor, moist products or
objects apart from packed goods.
 Printed information directly on the goods e.g. shoes, belts, tops,
must be readable and in a contrast color.
According to Quality Assurance Manual of Gap Inc.
"Anything which can harm the wearer of the product are
critical defects".

6.  Incorrect level mistake is also Critical Defect. All label errors are to be
considered as critical defects.
 Like-
 Care label with incorrect composition.
 Care label with incorrect care instructions.
 Incorrect Order Number on level and price tag.
 Incorrect size info on level and price tag.
 Incorrect or missing country of origin.
 Incorrect Instruction or assembling Direction, such as missing
instruction or Incorrect/inappropriate country of sales language.
 Incorrect carton/case-pack assortments within a shipping carton or
selling unit.
 Missing warning and recycle symbols on poly bags.

7.  Incorrect or missing R/N number.
 Incorrect or missing C/A number.
 Incorrect web address.
 Sharp Edge at Button or Zipper.
 Broken Needle in garments.
 Insect in the garments.
Note : Any Critical Defect found will fail the inspection.

8.  Major Defects are serious defects that affect appearance,
performance, durability or functionality to such a degree
that a customer would not buy the product if the saw the
defect. The defect would result in customer dissatisfaction.
 Major Defects are given below
 when the defect is noticeable to the customer and visible when
using the goods.
 when the defect does affect the quality of the goods .
 when the usefulness of the goods is affected .
 when the order is not packed according to the buyer Packing
Instruction Manual and the Order Packing Sheet

9. 1.Skip Stitch.
2.Fabric Defect.
3.Uncut Thread.
4.Loose Thread.
5.Joint Stitch.
6.Dirty Spot.
7.Shading.
8.Zipper wavy.
9.Back pocket high-
Low .
10.Needle mark.
11.Open Stitch.
12.Twisting.
13.Raw edge out.
14.Bar tack missing.
15.Insecure Stitch.
16.Puckering.
17.Pleat.

10. 2.01%
15.64%
10.38%
3.01%
0.91%
0.06%
5.37%
10.63%
4.75%
2.80%
5.73%
0.63%
6.22%
5.81%
0.89%
20.92%
1.48% 0.53%
2.30%
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
January-Individual Defects-Sewing

11. 20.92%
10.63%
15.64%
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
Uncut Thread Puckering Skip Stitch
Top Three Defects of Sewing line

13. RCA of the Defect CAP of the Defect Responsible Picture
Sewing machine
without trimming parts(
Wiper)
Need to attached thread
trimming parts (Wiper) in all
sewing machine.
Mechanic
Auto trimming part not
adjusted properly.
Need to add auto trimming
parts in the all Sewing
machine.
Mechanic
Operator and Helper
unconsciousness.
Sewing operator and Helper
need to more careful to
remove uncut thread.
Production
Supervisor/Line
Chief
Operator ignorance to
cut extra thread in his
own process.
Operator need to cut all
uncut thread in his own
process.
Production
Supervisor/Line
Chief.

15. Root Cause of the
Defect.
Corrective Action Plan Responsible
1.Seam Allowance not
maintain properly
1.Seam Allowance should maintain
properly.
Technician
2.Cut Panel measurement
Problem.
2.Cutting as per according to
measurement.
Cutting Department
3.Very poor quality machine
feed dog
3.Problematic machine feed need
to changed.
Mechanic

17. Root Cause of the
Defect.
Corrective Action Plan Responsible
Wrong type of needle for the
material.
Select the right type of needle for
the right fabric.
Technician
SPI not maintain properly. SPI should maintain properly. Technician
Poor quality thread type. Use good quality thread type. Technician
Operator unconsciousness. Operator should be conscious and
more attentive in his work.
Production
Supervisor/Line
Chief.
Tension variation in lopper
and needle thread.
Tension variation should be fixed up
in lopper and needle thread.
Production
Supervisor/Line
Chief.

18.  A Minor defect is a discrepancy from the standards, but
one that is not likely to affect the usability of an object.
when the defect is not noticeable to the customer and not visible
when using it .
when the defect does not affect the quality of the goods .
 when the usefulness does not affect the goods, but the quality is
not up to approved standard .

20.  A combination of 3 minor defects concentrated in the
same A zone will be treated as 1 major defect, (e.g.
upper front part if it is a garment)
 if 1 major defect is found together with minor defects on
the same product, the whole product should be counted
as 1 major defect .