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Apparel quality management part 1

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Apparel quality management part 1

  1. 1. QUALITY?QUALITY?
  2. 2. WHAT IS QUALITY?WHAT IS QUALITY? What would someone mean by the quality of a shoe? Let us suppose that it is a man’s shoe that he is asking about. Does he mean by good quality that it wears a long time? Or that it takes a shine well? That is feels comfortable? That it is waterproof? That the price is right in consideration of whatever he considers quality? Or it is good in design? Put another way, what quality-characteristics are important to the customer? - Deming
  3. 3. WHAT IS QUALITY?WHAT IS QUALITY? • Product qualityProduct quality is based on a product attribute.is based on a product attribute. How will you differentiate the quality between woven shirt andHow will you differentiate the quality between woven shirt and sweater?sweater? • User-based qualityUser-based quality is fitness for use,is fitness for use, How will you differentiate the quality betweenHow will you differentiate the quality between women garmentswomen garments andand kids garmentskids garments as a wearer?as a wearer? • manufacturing based qualitymanufacturing based quality is conformance to requirements,is conformance to requirements, Which quality parameters will be followed when manufacturingWhich quality parameters will be followed when manufacturing thermal wearthermal wear andand sweat jacketsweat jacket?? • value based qualityvalue based quality is the degree of excellence at anis the degree of excellence at an acceptable priceacceptable price Zara jacketZara jacket oror mango jacketsmango jackets are products gives value for moneyare products gives value for money
  4. 4. QUALITY types?QUALITY types? Assurance:Assurance: TheThe act of giving confidenceact of giving confidence,, thethe state of being certainstate of being certain or theor the act of making certainact of making certain.. Quality Assurance:Quality Assurance: TheThe planned and systematic activitiesplanned and systematic activities implemented in a quality system so that quality requirements forimplemented in a quality system so that quality requirements for a product or service will be fulfilled.a product or service will be fulfilled. Control:Control: An evaluation to indicate needed corrective responses;An evaluation to indicate needed corrective responses; the act of guiding a processthe act of guiding a process in which variability is attributablein which variability is attributable to a constant system of chance causes.to a constant system of chance causes. Quality Control: TheQuality Control: The observation techniquesobservation techniques andand activitiesactivities used toused to fulfill requirements for quality.fulfill requirements for quality.
  5. 5. • • DEFINITIONS OF QUALITYDEFINITIONS OF QUALITY • Conformance toConformance to specificationsspecifications • The degree to which aThe degree to which a productproduct oror serviceservice meets the needs of themeets the needs of the customercustomer • UniformityUniformity around a customer-around a customer- defined targetdefined target • ExceedingExceeding customer expectationscustomer expectations The customer is the most important part of the process.The customer is the most important part of the process.
  6. 6. FEWFEW RETURNSRETURNS IMPACT OF HIGHER QUALITY ON VALUEIMPACT OF HIGHER QUALITY ON VALUE HIGHERHIGHER QUALITYQUALITY LESS WAISTLESS WAIST LESSLESS REWORKREWORK FEWFEW REJECTIONREJECTION LESSLESS BACKLOGBACKLOG FEWFEW COMPLAINTCOMPLAINT SS LOWERLOWER COSTCOST HIGHHIGH PRODUCTIVIPRODUCTIVI TYTY HIGHERHIGHER VALUEVALUE
  7. 7. MARKETING &MARKETING & MARKETMARKET RESEARCHRESEARCH REQUIREMENTREQUIREMENT S &S & SPECIFICATIONSPECIFICATION DESIGN&DESIGN& DEVELOPMEDEVELOPME NTNT PROCUREMEPROCUREME NTNT PROCESSPROCESS PLANNING &PLANNING & DEVELOPMENTDEVELOPMENT PRODUCTIOPRODUCTIO NN INSPECTION,INSPECTION, TESTING &TESTING & EXAMINATIONEXAMINATION PACKAGINGPACKAGING && STORAGESTORAGE SALES&SALES& DISTRIBUTIDISTRIBUTI ONON INSTALLATIINSTALLATI ON&ON& OPERATIONOPERATION TECHNICALTECHNICAL ASSISTANCE &ASSISTANCE & MAINTENANCEMAINTENANCE DISPOSADISPOSA LL QUALITY MUST BE CONSIDER AT ALL STAGES IN THE LIFE CYCLE, ASQUALITY MUST BE CONSIDER AT ALL STAGES IN THE LIFE CYCLE, AS SHOWN BELOW, OF A PRODUCT.SHOWN BELOW, OF A PRODUCT.
  8. 8. Quality inspection in apparel industries “Visual examination or review of raw materials, partially finished components of garments and completely finished garments in relation to some standards, specifications, or requirements, as well as measuring garments to check if they meet the required measurements.”
  9. 9. QUALITY INSPECTION IN APPARELQUALITY INSPECTION IN APPAREL INDUSTRIESINDUSTRIES • Do to control quality of garments.Do to control quality of garments. • Checking of fabric,Checking of fabric, • Sewing thread,Sewing thread, • Button,Button, • Stitching,Stitching, • Zipper and other trims,Zipper and other trims, • Garments measurements/size etcGarments measurements/size etc according to required standard or specification isaccording to required standard or specification is known as inspection.known as inspection. Quality inspection is important for every sectionQuality inspection is important for every section of apparel industries.of apparel industries.
  10. 10. STEPS IN APPAREL INDUSTRIES TO CONTROLSTEPS IN APPAREL INDUSTRIES TO CONTROL QUALITYQUALITY RAW MATERIALRAW MATERIAL INSPECTIONINSPECTION IN PROCESS INSPECTIONIN PROCESS INSPECTION FINAL INSPECTIONFINAL INSPECTION
  11. 11. RAW MATERIALS INSPECTIONRAW MATERIALS INSPECTION It is done for the raw materials which are used inIt is done for the raw materials which are used in the apparel production likethe apparel production like fabric, sewing thread,fabric, sewing thread, button, other accessories etc.button, other accessories etc. It is also termed asIt is also termed as ‘incoming material inspection‘incoming material inspection.. Normally this is mainly done for fabrics usingNormally this is mainly done for fabrics using 44 point system or 10 point system.point system or 10 point system.
  12. 12. ONLINE OR IN-PROCESS INSPECTIONONLINE OR IN-PROCESS INSPECTION This is done during theThis is done during the manufacturing process so that ifmanufacturing process so that if there is any problem in the processthere is any problem in the process that will be rectifiedthat will be rectified in that stage itself.in that stage itself. This will be carried out by theThis will be carried out by the quality controllersquality controllers periodically sayperiodically say every two or three hoursevery two or three hours.. They will check the measurement and defects and makeThey will check the measurement and defects and make thethe inspection report which will be intimated to theinspection report which will be intimated to the
  13. 13. FINAL INSPECTIONFINAL INSPECTION This inspection is done afterThis inspection is done after the goods arethe goods are manufactured and packed in carton boxesmanufactured and packed in carton boxes and which areand which are ready for the shipment.ready for the shipment. The goods are inspected and will be graded as perThe goods are inspected and will be graded as per acceptable quality level (AQL)acceptable quality level (AQL) which is prescribed by thewhich is prescribed by the buyer.buyer. TheThe goods can be shipped after the final inspection isgoods can be shipped after the final inspection is
  14. 14. QUALITY INSPECTION IN APPARELQUALITY INSPECTION IN APPAREL INDUSTRIESINDUSTRIES IN SAMPLE MAKING SECTIONIN SAMPLE MAKING SECTION IN-MARKER MAKING SECTIONIN-MARKER MAKING SECTION INSPECTION IN FABRIC SPREADING SECTIONINSPECTION IN FABRIC SPREADING SECTION INSPECTION IN FABRIC CUTTING SECTIONINSPECTION IN FABRIC CUTTING SECTION INSPECTION IN FABRIC SEWN SECTIONINSPECTION IN FABRIC SEWN SECTION INSPECTION IN PRESSING & FINISHING SECTIONINSPECTION IN PRESSING & FINISHING SECTION
  15. 15. QUALITY INSPECTION IN SAMPLINGQUALITY INSPECTION IN SAMPLING MAINTAINING BUYER SPECIFICATION STANDARDMAINTAINING BUYER SPECIFICATION STANDARD CHECKING THE SAMPLE AND ITS DIFFERENT ISSUESCHECKING THE SAMPLE AND ITS DIFFERENT ISSUES MEASUREMENTS CHECKINGMEASUREMENTS CHECKING FABRIC COLOR, GSM, FASTNESS ETC PROPERTIESFABRIC COLOR, GSM, FASTNESS ETC PROPERTIES REQUIRED CHECKINGREQUIRED CHECKING SPI AND OTHER PARAMETER CHECKINGSPI AND OTHER PARAMETER CHECKING ANY OTHER DETAILING CHECKINGANY OTHER DETAILING CHECKING
  16. 16. QUALITY CONTROL IN MARKER MAKINGQUALITY CONTROL IN MARKER MAKING TO CHECK NOTCH OR DRILL MARKTO CHECK NOTCH OR DRILL MARK FABRIC WIDTH MUST BE HIGHER THAN MARKER WIDTHFABRIC WIDTH MUST BE HIGHER THAN MARKER WIDTH FABRIC LENGTH MUST BE HIGHER THAN MARKERFABRIC LENGTH MUST BE HIGHER THAN MARKER LENGTHLENGTH MATCHING OF GREEN LINEMATCHING OF GREEN LINE CHECK PATTERN SIZE AND DIMENSIONCHECK PATTERN SIZE AND DIMENSION MATCHING OF CHECK AND STRIPE TAKING INTOMATCHING OF CHECK AND STRIPE TAKING INTO CONSIDERATIONCONSIDERATION CONSIDERING GARMENTS PRODUCTION PLANCONSIDERING GARMENTS PRODUCTION PLAN PATTERN DIRECTION CONSIDERATION
  17. 17. FABRIC SPREADING ACCORDING TO CORRECTFABRIC SPREADING ACCORDING TO CORRECT ALIGNMENT WITH MARKER LENGTH AND WIDTHALIGNMENT WITH MARKER LENGTH AND WIDTH MAINTAIN REQUIREMENTS OF SPREADINGMAINTAIN REQUIREMENTS OF SPREADING LAY CONTAINS CORRECT NUMBER OF FABRIC PLYLAY CONTAINS CORRECT NUMBER OF FABRIC PLY CORRECT PLY DIRECTIONCORRECT PLY DIRECTION TO CONTROL THE FABRIC SPLICINGTO CONTROL THE FABRIC SPLICING TENSION CONTROLTENSION CONTROL QUALITY CONTROL IN FABRIC SPREADINGQUALITY CONTROL IN FABRIC SPREADING
  18. 18. The dimension of the pattern and the cut piece should be same and accurateThe dimension of the pattern and the cut piece should be same and accurate CUT EDGE SHOULD BE SMOOTH AND CLEANCUT EDGE SHOULD BE SMOOTH AND CLEAN NOTCH SHOULD BE CUT FINELYNOTCH SHOULD BE CUT FINELY DRILL HOLE SHOULD MADE AT PROPER PLACEDRILL HOLE SHOULD MADE AT PROPER PLACE NO YARN FRAYING SHOULD OCCUR AT CUT EDGENO YARN FRAYING SHOULD OCCUR AT CUT EDGE AVOID BLADE DEFLECTIONAVOID BLADE DEFLECTION MAINTAIN CUTTING ANGLEMAINTAIN CUTTING ANGLE QUALITY CONTROL IN FABRIC CUTTINGQUALITY CONTROL IN FABRIC CUTTING MORE SKILLED OPERATOR USING
  19. 19. INPUT MATERIALINPUT MATERIAL CHECKINGCHECKING SPECIAL WORK LIKE EMBROIDERY, PRINTINGSPECIAL WORK LIKE EMBROIDERY, PRINTING PANEL CHECKPANEL CHECK GARMENTS MEASUREMENTGARMENTS MEASUREMENT CHECKCHECK SIZE MISTAKE CHECKSIZE MISTAKE CHECK SHADE VARIATION WITHIN THESHADE VARIATION WITHIN THE CLOTHCLOTH CREASED OR WRINKLE APPEARANCE CONTROL QUALITY CONTROL IN SEWING SECTIONQUALITY CONTROL IN SEWING SECTION CUT PANEL AND ACCESSORIESCUT PANEL AND ACCESSORIES CHECKINGCHECKING MACHINE IS IN WELL CONDITIONMACHINE IS IN WELL CONDITION THREAD COUNTTHREAD COUNT CHECKCHECK NEEDLE SIZENEEDLE SIZE CHECKINGCHECKING STITCHING FAULT SHOULD BESTITCHING FAULT SHOULD BE CHECKEDCHECKED SEAM FAULT CHECKSEAM FAULT CHECK MISMATCHING MATCHING OFMISMATCHING MATCHING OF TRIMMINGTRIMMING WRONG PLACEMENT OFWRONG PLACEMENT OF INTERLININGINTERLINING
  20. 20. Proper inspection of the garments including measurement, spot, dirt,Proper inspection of the garments including measurement, spot, dirt, impurities Water spotimpurities Water spot IN SECURED OR BROKEN CHAIN ORIN SECURED OR BROKEN CHAIN OR BUTTONBUTTON PROPERLY DRIED IN AFTERPROPERLY DRIED IN AFTER PRESSINGPRESSING GET UP CHECKINGGET UP CHECKING QUALITY CONTROL IN FINISHING SECTIONQUALITY CONTROL IN FINISHING SECTION SHADING VARIATIONSHADING VARIATION CHECKCHECK SMOOTH AND UNFOLD INSMOOTH AND UNFOLD IN POCKETPOCKET PROPER SHAPE INPROPER SHAPE IN GARMENTSGARMENTS WANTED WRINKLE OR FOLD INWANTED WRINKLE OR FOLD IN LININGLINING COLLAR CLOSINGCOLLAR CLOSING SIDESIDE SEAMSEAM EVERY PARTS OF AEVERY PARTS OF A BODYBODY WRONG FOLDWRONG FOLD SLEEVE PLACKETSLEEVE PLACKET ATTACHATTACH CUFFCUFF ATTACHATTACH BOTTOM HEMBOTTOM HEM BACK YOKEBACK YOKE
  21. 21. • Done throughDone through Fabric Inspection machineFabric Inspection machine.. • Very important for every industries .Very important for every industries . • In fabric inspection their checks several things i.e. in fabricIn fabric inspection their checks several things i.e. in fabric are there anyare there any defect availabledefect available or not. In fabric, fabricor not. In fabric, fabric defects viz.defects viz. off shadeoff shade oror shade variationshade variation,, hole in fabrichole in fabric,, barre effectbarre effect etc. can be visual after entering into the storeetc. can be visual after entering into the store room. For those defects it will be problem able for makingroom. For those defects it will be problem able for making garments making.garments making. • In fabric inspection, also testIn fabric inspection, also test fabric strengthfabric strength,, colorcolor,, quantityquantity • To check fabric there are different system i.e. 4 pointTo check fabric there are different system i.e. 4 point system, 10 point system etc.system, 10 point system etc. FABRIC INSPECTIONFABRIC INSPECTION
  22. 22. FABRIC INSPECTIONFABRIC INSPECTION
  23. 23. FABRIC INSPECTIONFABRIC INSPECTION
  24. 24. FABRIC INSPECTIONFABRIC INSPECTION
  25. 25. During stitching fabric frequently brakeage of sewing thread is oneDuring stitching fabric frequently brakeage of sewing thread is one of the great problems for garments manufacturing.of the great problems for garments manufacturing. So that it is necessary to checkSo that it is necessary to check •THREAD CONSTRUCTION,THREAD CONSTRUCTION, •SEWABILITY,SEWABILITY, •COLOR,COLOR, •IMPERFECTION,IMPERFECTION, •FINISH, PACKAGEFINISH, PACKAGE •THREAD NUMBER,THREAD NUMBER, •THREAD PLY,THREAD PLY, •THREAD TENACITY,THREAD TENACITY, •THREAD ELONGATION,THREAD ELONGATION, •WINDING,WINDING, •YARDAGE OF SEWING THREAD.YARDAGE OF SEWING THREAD. SEWING THREAD INSPECTIONSEWING THREAD INSPECTION
  26. 26. The final quality of any garment is also affected by trims andThe final quality of any garment is also affected by trims and accessories applied in it.accessories applied in it. So that it is necessary to checkSo that it is necessary to check •BUTTON,BUTTON, •ZIPPERSZIPPERS •INTERLINING,INTERLINING, •LABEL &LABEL & •TAGSTAGS also need to check so that quality can be maintain according toalso need to check so that quality can be maintain according to required quality.required quality. FOR BUTTON,FOR BUTTON, •BUTTON STRENGTH,BUTTON STRENGTH, •BUTTON COLOR,BUTTON COLOR, •QUANTITY ETC ARE CHECKED.QUANTITY ETC ARE CHECKED. TRIMS AND ACCESSORIES INSPECTIONTRIMS AND ACCESSORIES INSPECTION
  27. 27. • 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 MAKINGMARKER MAKING • FABRIC SPREADINGFABRIC SPREADING • FABRIC CUTTINGFABRIC CUTTING • SORTING/ BUNDLINGSORTING/ BUNDLING • FABRIC SEWINGFABRIC SEWING • SEAM DEFECTSSEAM DEFECTS • ASSEMBLY DEFECTSASSEMBLY DEFECTS • PRESSING/ FINISHING DEFECTSPRESSING/ FINISHING DEFECTS IN PROCESS INSPECTIONIN PROCESS INSPECTION
  28. 28. 2. Distorted Grading:2. Distorted Grading: •Unbalanced patternsUnbalanced patterns which would causewhich would cause twisted seamstwisted seams,, •puckeringpuckering,, •pleatingpleating andand •a generala general uneconomical yardageuneconomical yardage waste.waste. PATTERN GRADING DEFECTSPATTERN GRADING DEFECTS 1. Grade Not Conforming to Specification1. Grade Not Conforming to Specification measurementsmeasurements •Finished productFinished product not measuring tonot measuring to specified dimensionspecified dimension •component partscomponent parts not fitting in relationship to notches,not fitting in relationship to notches, •openingsopenings andand seamsseams such as armholes sleeve headssuch as armholes sleeve heads neck bands,neck bands, •neck openingsneck openings andand side seams inseams,side seams inseams, •waist measurementswaist measurements and etc.and etc.
  29. 29. MARKERMARKER
  30. 30. MARKER INSPECTIONMARKER INSPECTION •• It is necessary to check all theIt is necessary to check all the parts of garments patternparts of garments pattern are inare in marker.marker. •• In markerIn marker labellinglabelling oror codingcoding of pattern should be checkedof pattern should be checked •• Pattern directionPattern direction should be checked.should be checked. •• PatternPattern grain linegrain line is very important thing which must beis very important thing which must be considered during marker making.considered during marker making. •• During marker making everyDuring marker making every pattern pieces dimensionpattern pieces dimension should beshould be accurate.accurate. •• During marker makingDuring marker making fabric lengthfabric length andand widthwidth should beshould be considered.considered.
  31. 31. MARKER INSPECTIONMARKER INSPECTION ••Notches & drill marksNotches & drill marks ••Knife clearanceKnife clearance ••Checks and stripes (mittering)Checks and stripes (mittering) ••Marker widthMarker width
  32. 32. MARKING DEFECTSMARKING DEFECTS Shaded Parts:-All component pans not included in same section. Pieces not Symmetrical:-Will not sew together without puckering or pleating. Not Marked by Directional Lines:-Bias will not lit together, causing twisting, puckering. pleating and a general mismatching of component parts. Skimpy marking:-Marker did not use outside perimeter of pattern. Notches and Punch Marks:-Left out., not clearly marked or misplaced. MarkerToo Wide:-Parts will not catch in lay, causing skimpy garments or requiring results.
  33. 33. MARKER DEFECTSMARKER DEFECTS Pattern moved after partially marked to fit into space.Pattern moved after partially marked to fit into space. MarkerToo Narrow:-MarkerToo Narrow:-Results In wasted materialResults In wasted material Mismatched Plaids-Mismatched Plaids-Marker did not block component parts toMarker did not block component parts to match.match. Misdirected Napping:-Misdirected Napping:-Patterns not marked in same direction andPatterns not marked in same direction and napped fabrics.napped fabrics.
  34. 34. SPREADINGSPREADING
  35. 35. Factors which must be checkedFactors which must be checked •Fabric NatureFabric Nature •Ply alignmentPly alignment •Ply tension/slacknessPly tension/slackness •BowingBowing •SplicingSplicing •Grain-lineGrain-line •Shade variationShade variation •Selvedge alignment & tightnessSelvedge alignment & tightness •Fabric widthFabric width •ChecksChecks •Static electricityStatic electricity SPREADING INSPECTIONSPREADING INSPECTION
  36. 36. 1.1. Uneven SpreadingUneven Spreading:-:-Front edgeFront edge o fo f lay is not even, resulting inlay is not even, resulting in front or back edge of marker not catching all ply.front or back edge of marker not catching all ply. 2.2. Narrow MaterialNarrow Material:-:-Bolts or rolls of material too narrow to coverBolts or rolls of material too narrow to cover marker width.marker width. 3.3. Missed Sectional BreaksMissed Sectional Breaks:-Sectional marker breaks too long or:-Sectional marker breaks too long or too short. Parts in lay will be short or material wasted.too short. Parts in lay will be short or material wasted. 4.4. ImproperTensionImproperTension:-Cloth spread too tight or too loose, causing:-Cloth spread too tight or too loose, causing parts not to fit in sewing or distorting dimensions of garments.parts not to fit in sewing or distorting dimensions of garments. 5.5. Mismatching PlaidsMismatching Plaids:-:-Material spread too loose or too tightMaterial spread too loose or too tight causing plaid lines to run diagonally or bow.causing plaid lines to run diagonally or bow. 6.6. Misdirected NappingMisdirected Napping:-:-Air pockets not removed. NappedAir pockets not removed. Napped material reversed in spreading.material reversed in spreading. 7.7. ImproperMatching of Face of MaterialImproperMatching of Face of Material:-Not spread face:-Not spread face down, face up or face to face as required.down, face up or face to face as required. SPREADING DEFECTSSPREADING DEFECTS
  37. 37. FRAYED EDGEFRAYED EDGE
  38. 38. FUZZY, RAGGED OR SERRATED EDGESFUZZY, RAGGED OR SERRATED EDGES
  39. 39. Marker MakingMarker Making ↓↓ Fabric SpreadingFabric Spreading ↓↓ Placing Marker Paper on to the LayPlacing Marker Paper on to the Lay ↓↓ Fabric CuttingFabric Cutting ↓↓ NumberingNumbering ↓↓ 100% checking & Parts Replacing if needed.100% checking & Parts Replacing if needed. ↓↓ Shorting & BundlingShorting & Bundling ↓↓ Sewing/AssemblingSewing/Assembling CUTTING INSPECTIONCUTTING INSPECTION
  40. 40. ••Ply to ply fusionPly to ply fusion ••Single edge fusionSingle edge fusion ••Pattern precisionPattern precision ••Notches & drillersNotches & drillers ••Cutting Equipment precisionCutting Equipment precision CUTTING INSPECTIONCUTTING INSPECTION
  41. 41. 1.1. Misplaced Piece Rate Tickets or Bundle MembersMisplaced Piece Rate Tickets or Bundle Members:-:-Attached to, or markedAttached to, or marked on,on, wrong bundles, causing mixed sizeswrong bundles, causing mixed sizes or land shades.or land shades. 2.2. Drill MarksDrill Marks:-:-Drill marks misplaced,Drill marks misplaced, not perpendicularnot perpendicular, omitted or wrong side, omitted or wrong side drill used.drill used. 3.3. Opening SlitsOpening Slits:-:-Cut under above to the side or atCut under above to the side or at incorrect angleincorrect angle. Not cut. Not cut through entire bundle or omitted.through entire bundle or omitted. 4.4. Improper CuttingImproper Cutting:-:-Not following marker lines, resulting in distorted parts.Not following marker lines, resulting in distorted parts. Letting knife lean causing top and bottom ply to be of different sizes.Letting knife lean causing top and bottom ply to be of different sizes. 5.5. NotchesNotches:-:-Misplaced, too deep, too shallowMisplaced, too deep, too shallow or omitted.or omitted. 6.6. Oil Spots:-Oil Spots:-EquipmentEquipment improperly oiledimproperly oiled or cleaned.or cleaned. 7.7. ImproperKnife Sharpening:-ImproperKnife Sharpening:-Causing ragged, frayedCausing ragged, frayed or fused edges onor fused edges on bundles.bundles. CUTTING DEFECTSCUTTING DEFECTS
  42. 42. It is necessary to check numbering, sorting, andIt is necessary to check numbering, sorting, and bundling is done accurately.bundling is done accurately. SORTING/ BUNDLINGSORTING/ BUNDLING DEFECTSDEFECTS 1.1. Not Stacked in Numerical Order:Not Stacked in Numerical Order: BundleBundle numbers not in order on rack skid or box.numbers not in order on rack skid or box. 2.2. Matching Linings:Matching Linings: Wrong size or wrongWrong size or wrong material.material.
  43. 43. • Stitching DefectsStitching Defects • Needle damageNeedle damage • Skipped stitchSkipped stitch • Thread breaksThread breaks • Seam puckerSeam pucker • Wrong stitch densityWrong stitch density • Uneven stitchUneven stitch • Staggered stitchStaggered stitch • Improperly formed stitchImproperly formed stitch SEWING INSPECTIONSEWING INSPECTION
  44. 44. Skip stitchesSkip stitches •Improper threading. •Poor clamping or insufficient pressure (flagging). •The needle needs replacing. •Wrong size needle. •Wrong type of needle for the material. •Lubrication. •Wrong thread for the application. •Poor quality thread. •Needle size and thread weight are mismatched. •Worn thread guides, paths or eyelets

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