Sewing Machine Operator Recruitment, Grading and Skill Matrix

Sewing Machine Operator Recruitment

Sewing operator recruitment is a tough job in the apparel industry. To recruit the best quality and efficient operator, sewing operators have to stitch one, two or three bundle garments with good seam quality by a certain time, recruiter checks his/ her production capacity and product quality and can be seen how many operations an operator can do, these few criteria set his grading. Then, Grade, wise operator salary is fixed by sewing operator recruiter, garments manufacturer have own operator grade wise salary standard. Here in this article, you will have details idea of Sewing Machine Operator Recruitment, Grading and Skill Matrix.

Sewing Machine Operator Recruitment, Grading and Skill Matrix in Garments

Related articles you may like:

  1. The job description of a sewing operator
  2. List of the sewing machine used in garments
  3. Different parts of a sewing machine

Sewing Operator Grading

Lots of factors have to consider when doing operator grading. First, we have to know what type of operation operator does, then the operator’s production efficiency and many others factor. Here you can see below information on how to grade sewing operator.

Sewing Operator Grading

SN. Operation Name M/C Type
“A” Grade Category
1 Pocket Attach SN
2 Placket Attach SN
3 Collar Attach SN
4 Collar Close SN
5 Zipper Join SN
6 Zipper Top Stitch SN
7 Placket Box Make SN
8 Neck Join OL
9 Sleeve Join OL
10 Side Seam OL
11 Bottom Join OL
12 Nk Piping  FL
13 Bottom Hem FL
14 Waist Band T /S Kansai
“B” Grade Category
1 Placket 1/16 Top Stitch SN
2 Bk Nk T/S (LBL T/S) SN
3 Back Rise Join OL
4 Front Rise Join OL
5 Shoulder Join OL
6 Front Nk T/S FL
7 Bk Nk Binding FL
8 Sleeve Hem FL
9 Arm Hole T/S FL
10 Shoulder Join OL
“C” Grade Category
1 Collar Tack SN
2 Side Vent Tack SN
3 Sleeve Inside tack SN
4 Sleeve Out Side Tack SN
5 BTN Hole BH
6 BTN Stitch BS
7 Bar Tack BT

Here,

  • SN – Single needle sewing machine
  • OL  -Overlock sewing machine
  • FL – Flat lock sewing machine
  • BH – Buttonhole sewing machine
  • BS – Button stitch sewing machine
  • BT – Bartack sewing machine

Explanation of Sewing Machine Operator Grading

  • For the each A grade operation giving 10 marks for 100% efficiency level up to a maximum of 8 operations, marks will be multiplying by the efficiency Percentage. (Example: 10X 0.7, if the efficiency level 70%.)
  • For each B grade operation giving 7 marks for 100% efficiency level up to a maximum of 8 operations, marks will be multiplying by the efficiency Percentage. (Example: 7X 0.7, if the efficiency level 70 %.)
  • For each C grade operation giving 5 marks for 100% efficiency level up to a maximum of 8 operations, marks will be multiplying by the efficiency Percentage. (Example: 5 X 0.7, if the efficiency level 70 %.)

General Grading of Sewing Machine Operator

  1. 10 marks will be given if the absenteeism less than 3%
  2. 5 Marks will be given for over one-year service in the factory
  3. 1 to 10 Marks will be given for types in satisfaction level of production management.
  4. To be an ‘A’ grade operators must have the ability to operate 3 different machine
  5. To be a ‘B’ grade operators, must have the ability to operate 3 different machine

Final Grading Based Marks of Sewing Machine Operator

  • 80> GRADE A
  • 70 > 80 GRADE B
  • 60 > 70 GRADE C

Sewing Operator Skills Matrix

Sewing operator skill matrix or summary is a database of operator production capacity of different operation, number of machine and operation with the name he can operate, these process efficiency, salary, date of join. The database makes in Excel (spreadsheet), keeping by IE department in the apparel industry. This database help factory to migrate operator to another operation, to find out best sewing operator easily, to do operator grading easily.

Sewing Machine Operator Recruitment, Grading and Skill Matrix

Sewing Operator Skill Summary List

  1. Number of operation can sew
  2. Number of sewing machine can operate
  3. Production capacity per operation
  4. Sewing efficiency
  5. Servicing period in factory
  6. Seam quality

Sewing Machine Operator Recruitment, Grading and Skill Matrix in Garments pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Overlock Sewing Machine Types, Specifications and Technical Adjustment

Overlock Sewing Machine

The overlock machine is different from the lockstitch sewing machine, cut the edge of fabrics and cover two parts of fabrics by stitching. Overlock machine has different types of specification, from 2/3 to 6 threads can be used. Here in this article, we will have detail discussion of Overlock Sewing Machine Types, Specifications and Technical Adjustment.

Overlock Sewing Machine

Overlock Sewing Machine Types, Specifications and Technical Adjustment

Overlock Stitch

Types of Overlock Sewing Machine

An overlock / over edge machine is a high-speed sewing machine. This is the quickest performing machine for giving overedge stitches. Overlock Machines Are available in following Specifications

  1. 2 Thread Overlock machine
  2. 3 Thread Overlock Machine
  3. 4 Thread Overlock Machine
  4. 5 Thread Overlock Machine
  5. 6 Thread Overlock Machine

Overlock Sewing Machine Types, Specifications and Technical Adjustment

The Relationship between Overlock Machine and Number of Thread Used

Serial No. Machine Name No. Of Threads use Total threads use
Needle Looper
1 2 Thread Overlock Machine 1 1 2
2 3 Thread Overlock Machine 1 2 3
3 4 Thread Overlock Machine 2 2 4
4 5 Thread Overlock Machine 2 3 5
5 6 Thread Overlock Machine 3 3 6

Features of Overlock Sewing Machine

  1. Maximum Machine speed 6500 SPM (vary operation wise)
  2. Stitch can be made using 2,3,4,5 or 6 threads, depending on the no. of needles and looper
  3. Stitch length 2 to 4 mm
  4. Stitching type- Overlock stitch
  5. Used feed is Deferential feed
  6. Oil lubrication system- Automatic
  7. Used in Woven, knit; all types of garments

Technical Adjustment of Overlock Machine

Technical adjustments which are to be taught while dealing with OVERLOCK machines are given below. Trainers should keep the following points in mind during the session of OVERLOCK machine

  • First, demonstrate the adjustment then ask trainee to practice on the machine.
  • Use the Instructional manual given by the machinery supplier during Session
  • Make sure, all the trainees are able to understand the Instructional manual.
  • The practice of sewing on a machine is also necessary.

Technical Adjustments Points of Overlock Machine

  1. Basic Machine Practice
  2. Technical Specification
  3. Installation of needle
  4. Needle bar Height adjustment
  5. Needle to lower looper timing
  6. Upper Looper Timing
  7. Chain looper timing (Safety Stitch)
  8. Upper Knife Adjustment
  9. Lower Knife adjustment
  10. Feed Dog Height adjustment
  11. Cam Timing
  12. Thread Adjustment

Overlock Sewing Machine Types, Specifications and Technical Adjustment pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Sewing Machine Parts: Name, Functions, Sourcing, and Maintenance

Sewing Machine Parts: Name, Functions, Sourcing, and Maintenance

What is a Sewing Machine? A sewing machine is a unique designed machine which is used for stitching different parts of fabric together to make garments products. Sewing machines are used in both lather and apparel industry. The main functions of sewing machine are sewing fabric or any other parts of materials. Earlier people used to sew by hand but after the industrial revolution mechanical machine was created which is a handheld sewing machine. Because of continuous development now we have automated sewing machine available for home use, commercial use and industrial use. Although basic sewing functions remain the same, the pattern of stitches are different and improved one. By using the modern sewing machine, you can put different types of the stitch as required. For a good finished product, you need to buy a good quality sewing machine, either you can buy manual or automated. For personal use, you can buy a handheld sewing machine. Now with a modern machine, you can not only sew your cloth but also can do embroidery. A good quality thread is required for getting better finishing and sewing strength. Here I will discuss all the different parts of a sewing machine both for traditional and modern, manual and automatic sewing machine and also Sewing Machine Parts: Name, Functions, Sourcing, and Maintenance at a glance.

Different Parts of a Sewing Machine

You may think about what brand you should choose among available sewing machine brands. My suggestion for you first determines for what purpose you are going to purchase the sewing machine. There are many popular sewing machine brand available out there. Brother, Juki, Singer, and Janome are the most widely used brands. If it is for home, use purpose then singer machine you can purchase. You may find, for industrial garments production Juki, Brother these two brands are highly used.

To get long-term service from a sewing machine, you have to take care of it. Regular maintenance and cleaning are necessary. You also need to put lubricants or oil into the required parts. Sewing Machine Parts can be imported from China or buy from the local market. Needle, bobbin, bobbin case, oil, and lubricants are commonly used parts and maintenance materials.

All Parts of Traditional and Modern Sewing Machine

Sewing Machine Parts, All parts of Sewing Machine

Sewing Machine Parts

  1. Balance Wheel
  2. Bobbin Winder
  3. Face Plate Thumb Screw
  4. Feed Dog
  5. Needle Bar Bushing
  6. Needle Bar Thread Guide
  7. Needle Clamp Thumb Screw
  8. Needle Clamp
  9. Needle
  10. Presser Bar Lifter
  11. Presser Foot Thumb Screw
  12. Presser Foot
  13. Pressure Regulating Thumb Screw
  14. Spoon Pin
  15. Tension Discs
  16. Tension Spring
  17. Thread Guide
  18. Thread Take Up Lever
  19. Thread Take Up Spring
  20. Throat Plate
  21. Stitch Indicator Plate
  22. Stitch Regulator
  23. Stitch Regulator Thumb Screw
  24. Bobbin Winder Thread Tension
  25. Bobbin Winder Spool Pin
  26. Needle Plate
  27. Bobbin Case
  28. Bobbin

Name of Different Parts of  a Sewing Machine

Balance Wheel of Sewing Machine

In a traditional handheld sewing machine and a semi-auto sewing machine, you can see that there is a wheel on the top right corner of a sewing machine. Basically, it is used to run the machine manually.

The needle of Sewing Machine

A needle is a sharp metal, very sharp in nature which has a small hole (eye) in which a thread go through. Basically, a needle is used for sewing. In a sewing machine, a needle is attached. In a needle, you may find 5 parts. They are a shank, Shaft, Front Groove, Point Scarf, and eye. For woven fabric and denim, lather, knit fabric, different types of Needle are used. Needle made of steel coated with chrome or titanium.

Needle of Sewing Machine

Different Size of Sewing Machine Needle

According to the purpose, Different sizes of a needle are used for different types of fabric

Different Size of Needle for Different Types of Fabric

Sourcing of Sewing Machine Parts: Needles

sewing machine needle is mainly sourced from China because of a cheap price. So can also source it locally if the order quantity is less.

Spool Pin of Sewing Machine

Spool pin in a sewing machine is placed vertically or horizontally which actually used for holding the spool of threads. This is a fixed part of a sewing machine.

The Bobbin of Sewing Machine

In a sewing machine bobbin is one of an integral part and it is non-electrical parts of a sewing machine. Bobbins can be found in different electric devices. In a bobbin, threads are wired which is used for sewing. You need to set the required thread into a bobbin. After finishing you have to refill the bobbin to continue sewing.

Sourcing of Sewing Machine Parts: Bobbin

There are many popular brands of bobbin manufacturer, you can collect bobbin from them. You can source either by importing or if locally available then purchase it locally because it will be cheaper. Different manufacturers of sewing machine bobbins are:

  • Brother
  • Juki
  • Janome
  • Singer
  • Boby Lock
  • Bernina
  • Consew
  • Elena
  • Kenmore
  • Riccar
  • Handi Quilter

Bobbin Holder of Sewing Machine

Bobbin holder is used to holding the bobbin into the sewing machine. Bobbin holder also is known as bobbin case which is one of the key sewing machine parts. Time to time you may need to conduct cleaning and maintenance or change of bobbin case. It is one of the commonly used spare parts of a sewing machine.

Presser Foot of Sewing Machine

presser foot using in a sewing machine to hold the fabric in the right place on the throat plate so that fabric cannot slip around. You may need to change your sewing machine pressure foot if you use your machine for commercial production.

Tension Discs and Tension Spring

The tension discs used to control the thread tension to give proper stitch on the fabric. If there is a problem of tension then you may see that stitch is not placing properly, it may loose or tight. Tension spring is added to control the pressure so that two different fabric can join together with proper stitch. Tension discs and spring may need to change if it is damaged. You can purchase it locally or source it from China if you need a large quantity.

Tension Discs and Spring of Sewing Machine

Remember that you have to clean dust time to time from the tension discs otherwise your may find improper stitch.

Face Plate Thumb Screw

Faceplate thumb screw is used for attaching the face plate of a sewing machine. You may find it a traditional sewing machine. Normally, this part is not required to replace.

Thread Guide

Thread guide is a small part of a sewing machine which has a hole inside, is responsible to properly guide the threads from spool pin to the hole of a needle. Thread guide is made of steel or metal.

Throat Plate

Throat plate is placed between pressure foot and bobbin case. This plate also is known as needle plate. It is made of metal. At the time of sewing, pressure foot is placed on top of the throat plate.

Stitch Indicator Plate

Stitch Indicator plate indicates the stitching type where different stitching number is written. This plate is a fixed part of a sewing machine which is not required to change but you should clean the surface of the plate so that written number is visible.

Stitch Regulator

By using a stitch regulator you can regulate the type of stitch on the fabric. In accordance with your requirement, you can switch into a different stitch or adjust your sewing stitch.

Bobbin Winder

Bobbin winder basically ensures the right direction of the threads from the spool to the bobbin. This is a mechanical process which is done automatically inside the sewing machine.

Feed Dog

Feed dog helps to feed the fabric to the required direction, either backward or forward using its teeth. Feed dog is made of metal. Normally it is not a visible part of a sewing machine. But if you look closely into the needle plate then you can see. If feed dog is damaged then you must need to change it.

Maintenance of Sewing Machine Parts

Finally, a sewing machine should be properly maintained to get long lasting service. If you do not clean and add lubricant properly then you may find a technical problem or not functioning properly. Different defects you may identify. How you can ensure proper maintenance?

  • First, read the manual provided with the sewing machine and follow the guidelines for setting the machine and starting sewing.
  • Please clean after using if there is any dust.
  • Do not give extra pressure if a thread is stuck in the bobbin case
  • Use good quality accessories
  • Regularly put good quality lubricants to the right place.

Parts of Sewing Machine pdf

If you have any confusion or you want to add value to this article then please let me know.

Written by

Md. Nahian Mahmud Shaikat

Features of Single Needle Lock Stitch Machine

Features of Single Needle Lock Stitch Machine

Single needle lock stitch machine is called a plain needle sewing machine. Single needle lock stitch machine is mostly used as an industrial sewing machine. Modern single needle lockstitch has a thread trimmer which operates at the highest speed of its kind. Lockstitch machine is the most commonly used sewing machine in the apparel industry, especially in woven garments. Here in this article, I am going to share Features of Single Needle Lock Stitch Machine with you for a clear understanding of single needle lock stitch sewing machine.

Types of Lock stitch Sewing Machine

There are two types of lock stitch sewing machine used in a garments factory.

  1. Single needle lockstitch machine
  2. Double(two) needle lockstitch machine

Single Needle Lock Stitch Machine

Single needle lock stitch machine is stitch by one needle of a machine by lock stitch.

Double Needle Lock Stitch Machine

Double-needle /twin/two needle is a needle with a single shank and two shafts, proceed stitching with the double stitching you will get two parallel rows on the face of the fabric and a zig-zag stitch on the back of the fabric.

You may also love to read:

Parts of Single Needle Lock Stitch Sewing Machine

Different Parts of Single Needle Lock Stitch Sewing Machine

Different Parts of Single Needle Lock Stitch Sewing Machine

  1. Bobbin Winder
  2. Thread wiper device
  3. Lifting lever
  4. Hand swatch A
  5. Hand swatch B
  6. Work Clamp
  7. Knee lifter plate
  8. Power stitch
  9. Oil gauge window
  10. Oil feeding pocket
  11. Machine pulley
  12. Operation panel
  13. Cotton stand
  14. Control box
  15. Power indicator
  16. USB port
  17. Pulley cover
  18. The thread takes up cover
  19. Finger guard

Parts of Single Needle Lock Stitch Sewing Machine

Features of Single Needle Lock Stitch Machine

  1. Two thread need for a machine, one for needle and another one for bobbin
  2. Needle thread set in the upper side of fabric and bobbin thread set in the lower side of the fabric in stitch
  3. Stitching type only lock stitch
  4. Machine speed is 4000-5000 RPM
  5. 1 needle in every machine
  6. Edge cutting, automatic bobbin winding
  7. Less noise, low vibration, no radiation, and environment-friendly
  8. SPI generally 7-9
  9. Sewing Shirts, Jackets, Suits, Over-coats, Bed covers, Curtains, Children’s clothes, Bags, Leather, Wool, Chemical fiber and Canvas.

Features of Single Needle Lock Stitch Machine

Technical Specifications of Lock Stitch Machine

  1. Basic Machine Practice (Loop Exercise)
  2. Technical Specification
  3. Installation of needle
  4. Needle bar Height adjustment
  5. Hook Set Timing
  6. Feed Dog adjustment and alignment
  7. Feed Dog Eccentric cam Adjustment
  8. Pressure foot to the Pressure adjustment

Features of Single Needle Lock Stitch Machine pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

List of Sewing Machine Used in Apparel Industry

List of Sewing Machine Used in Apparel Industry

Industrial Sewing Machine in the Apparel Industry: Nowadays different sewing machines are used in the apparel industry for a different purpose and all are an electrical sewing machine. This machine is the improved version of a traditional sewing machine. The sewing machine is being used after the industrial revolution. It is important to know all types of the sewing machine used in the garments industry if are a garment professional. If you are involved with the RMG sector, then you have to know about the sewing machine and their functions.  In this article, I made a list of sewing machine used in apparel industry.

You may also like to read: List of machine use in knitting knit dyeing and Knit garments

List of Sewing Machine Used in Apparel Industry

List of Sewing Machines Used in Garments

  1. Single Needle Lock Stitch machine (Plain machine)
  2. Double-needle lockstitch machine
  3. Three thread Over Lock Machine
  4. Four thread overlock machine
  5. Five thread overlock machine
  6. Six thread Over Lock Machine
  7. Flatlock machine
  8. Two Needle Vertical machine
  9. Single needle Chain stitch machine
  10. Two needle chain stitch machine
  11. Kansai machine
  12. Feed of the arm
  13. Saddle stitch binding sewing machine
  14. Bar tack machine
  15. Velcro attach machine
  16. Velcro automatic cutting machine
  17. Buttonhole machine
  18. Button stitch machine
  19. Eyelet hole machine
  20. Snap button attach machine
  21. Blind stitch machine
  22. Zigzag machine
  23. Label cutter machine
  24. APW sewing machine
  25. Rectangular Sewing machines
  26. Embroidery machine
  27. Automatic 2-needle Belt-loop Attaching Machine
  28. Decorative Stitch Machine
  29. Cover stitch machine
  30. Round hole machine

List of the Sewing machine used in Apparel industry pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Preventive Machine Maintenance Checklist for Sewing Machine

Preventive Machine Maintenance in Garments

Preventive maintenance refers to regular, routine maintenance to help keep equipment up and running, preventing any unplanned downtime and expensive costs from unanticipated equipment failure. Preventive maintenance reduces cost, reduce machine downtime. These are the reasons why preventive machine maintenance in garments is required. A sewing machine is one of the key machinery used in garments industry to make garments. Because of sewing machine breakdown, or any other mechanical problem may stop your factory production. So to reduce this problem it will be useful if you do maintenance of machine regular basis. For your convenience, I made a Preventive Machine Maintenance Checklist for Sewing Machine. Hopefully, this will help you to make a checklist and continue your sewing machine maintenance to minimize the problem. Here is the list is given below:

Preventive Machine Maintenance Checklist for Sewing Machine

Preventive Machine Maintenance Checklist for Sewing Machine

  1. Thread stand clean & tight
  2. Bobbin winder proper check
  3. Feed dog check
  4. Pressure foot check
  5. Needle plate check
  6. Needle screw check
  7. V-belt check
  8. Belt cover clean & tight
  9. Pully & pully cover check
  10. Hookset check
  11. Oil level check properly & clean
  12. Needle guard check
  13. Moving knife check
  14. Fix knife check
  15. Footrest check
  16. Headrest pin check
  17. Kneepad check
  18. Paddle mat check
  19. Ubt machine proper working & check
  20. Stand shoe check
  21. Fabric guide check
  22. Pedal chain check
  23. Looper check
  24. Waste tube check
  25. Lower knife check
  26. Upper knife check
  27. Eyeglass check
  28. Tabletop condition check
  29. Machine condition check
  30. Gauge set check
  31. Top feed dog check
  32. Gear bearing check
  33. Pressure bar/regulator check
  34. Bobbin case check
  35. Oil lubrication system checking
  36. Oil change
  37. Moto & control box clean by air pressure
  38. All moving parts checking/replacement
  39. Gear and bearing checking/replacement
  40. Hook for sharp surfaces and burrs on the hook point
  41. Check the oil levels in the machines

If you have any confusion then please let me know. I will try to clarify for your better understanding.

Preventive Machine Maintenance Checklist of Sewing Machine pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Sewing Defects Solve with Root Causes

Sewing Defects Solve with Root Causes and Corrective Actions

Reducing sewing defect is the key task for garments quality management and it is one of the challenging jobs. This article is all about solving sewing defects/faults. Here I have listed total 15 defects of garments, root causes and corrective action to reduce them. After reading this article hopefully, you will be able to know how it is possible to reduce Sewing Defects Solve with Root Causes.

Sewing Defects Solve with Root Causes

Sewing Defects Solving Process

In a sewing defects solving process you may commonly find the following process. This one is a continuous process where you need to follow to solve your sewing defects problem in a garments industry.

  1. Find out top defects respective areas
  2. Find out Root causes by the 6M method
  3. Taking corrective action
  4. Assign work of a responsible person
  5. Keep statistical data
  6. Follow up improvement

Sewing Defects Solving Process

Root Causes of Garments Defects

Manufacturers have to find out all causes behind defect to work on it. As a quality control person, you need to do practical work in defect occurring place to find out all the reasons behind every defect. The best method is to follow the 6M method for Cause and Effect Analysis. 6M is finding root causes against 6 criteria. 6M’s are

  • M – Machinery
  • M – Manpower
  • M – Mother-nature
  • M – Method
  • M – Materials
  • M – Measurement

Corrective Action of Sewing Defects

Corrective action is to solve or correct the problem which considers as a defect. Action should be specific and work should be divided to related responsible person. This is a very effective way to solve defects. In this article, I gave corrective action against each and every defect those normally visible. Total fifteen defects are there and for these defects what are the root cause and how we can minimize these problems are also given below in a chart.

  1. Broken stitches
  2. High-low
  3. Puckering
  4. Oil / stain / dirt / rust/spot
  5. Fullness
  6. Stitches skipped
  7. Incorrect operation
  8. Untrimmed threads
  9. Crooked
  10. Shining mark
  11. Poor repair
  12. Hole
  13. Washing effect poor
  14. Off shade
  15. Puckering

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SL Defects Root Causes  Corrective Action 
1 BROKEN STITCHES 1. Tension is too tight 1. Correct machine adjustment
2. Poor thread quality 2. Take initiative to ask the supplier for a better quality thread.
3. The wrong thread size 3. Machine maintenance team have to check every machine speed routine wise.
4. The machine running in over speed
2 HIGH / LOW 1. Operator negligence 1. Train up sewing operator for stitching incorrect seam point.
2. Marking up down 2. Marking to marked correctly, sewing supervisor is responsible for it.
3. Incorrect cut mark 3. Correct cut mark and proper use of sewing guide will be ensured.
4. Some operator not using guide
3 OIL / STAIN / DIRT / RUST/SPOT 1. Poor garments handling at Cutting and sewing 1. Proper fabrics/garments handling from fabric inspection to finishing to get rid of a spot
2. Poor machine maintenance as a result of oil leakage   2. Correct machine maintenance and oil leakage checking will be ensured by sewing maintenance team
3. A spot in washing 3. Especially spot checking after washing and keeping clean work area
4. Dirty workplace
4 FULLNESS 1. Tension too tight 1. Correct machine tension and adjustment                                                                       
2. Incorrect machine adjustment 2. Train up sewing operator of proper handling of sewing
3. Unskilled operator 3. Checking machine speed regularly
4. The machine running in over speed
5 STITCHES SKIPPED 1. Failure of hook or looper and needle to enter the loop at correct time 1. Proper hook, looper, and needle to enter the loop at a correct time
2. Irregular thread tension on upper or lower loop 2. Proper thread tension on upper and lower loop
3. Due to needle deflection 3. Needle change as per procedure
4. Wrong Seam Width 4. Keeping right seam width
6 INCORRECT OPERATION 1. Inefficient operator. Not following the approved sample 1. Proper education and counseling of Supervisor to each and every operator during the start of any operation. Ensure that stitching should follow the approved reference sample.
2. Operator not checking his own work before passing to next process  2. The supervisor should advise the operator to do self-inspection. In line, QC should check on this and make a record on those operators not doing self-inspection to check their performance.
3. Mishandling of cut panels during stitching. 3. Ensure that Sewing Supervisors are giving proper instruction to the operator for proper sewing technique
4. Negligence of Supervisor and they do not check the work of the operator. 4. Sewing QA in-charge and supervisor with coordination with GPQ team should ensure that all any operations are confirmed before bulk production to avoid any mistake.
5. In line QC not doing proper checking per operation during the in-line audit. 5. In line, QC should strictly follow the procedure of inspection.
6. Machine not properly adjusted 6. Ensure that mechanic adjust properly the machines before bulk production.
7 OIL STAIN/ DIRT/RUST 1. Poor housekeeping and handling of garments. 1. Maintain good housekeeping in the working area. Sewing & Finishing In Charge should ensure their working place is in order, neat and clean.
2. Some machines with oil leakage     2. Educate and train quality inspector for the proper inspection method.
3. Lacking proper machine maintenance  3. Maintenance department should ensure that every machine will have a maintenance checkup once a week. Ensure proper oiling level to be maintained to prevent leaking of machine oil.
4. Dirty workplace  4. Application of scrap paper under the presser foot of sewing machines after the day’s work so that machines will oil leakage can be traced.
5. Negligence of Quality Inspector to identify the defect during final checking 5. No idle machines in Sewing Line & Cover all the idle machines
6. No garments to put around the machine head
7. An operator should clean the machine before and after use
8. Cover input box and machines after working time
9. Do not sleep on top of garments
8 UNTRIMMED THREADS 1. Carelessness of Quality inspector. Not following the proper method/sequence of inspection 1. Motivation and training of quality Inspector for proper work attitude
2. If found excess thread operators/workers are pulling and breaking it instead of cutting the excess thread ends 2. Conduct training for all quality for proper inspection method. Ensure to follow the proper sequence of inspection in order not to miss any process
3. Operator not doing self- trimming after the process is finished 3. QAD In charge should check and monitor the work of inspectors. All garments found with the uncut thread based on inspection report must be advised to all concerned operators  and sewing supervisors for proper corrective action to avoid garments passed to next process with the uncut thread
4. Improper method of trimming. 4. Ensure that workers are following the proper method of trimming and operators are doing self-trimming. The quality inspector should check this during the in-line audit
5. Not following the proper method
6. Improper finishing
9 CROOKED 1. Mishandling of the operator. 1. Proper training for an operator for correct material handling technique. Ensure that pattern and marking guide is accurate. Ensure appropriate presser foot is used
2. Not maintain the proper sewing procedure 2. Motivation and training of Quality Inspector on proper work behavior. Ensure that proper method of inspection is being followed all the time.  GPQ and QAD In charge should conduct an audit every hour to check the quality.
3. Lack of concentration of quality inspector
10 SHINING  1. Carelessness of presser. Lack of concentration 1. Motivation and training of presser for proper ironing method and technique
2. Overheated iron and steam control sometimes malfunctioned 2. Before start ironing garments, first, check if the iron surface is clean. Ensure that the ironing board is well padded
3. Ironing is too heavy and applies too much pressure 3. Use proper temperature during iron. Ensure that steam amount is appropriate and functioning properly
4. Iron must heat completely before use. Ensure to use iron shoes at all times
5. Follow correct iron method and ensure not to put heavy pressure
11 POOR REPAIR 1. Unskilled repairing operator 1. Train up repairing operator
2.Poor superstation 2. Strengthen supervision  and quality checkpoint
3.Production pressure 3. Reduce workload
12 HOLE 1. Poor garments handling at Cutting and sewing 1. Proper garments handling in every section up to finishing
2. A sharp edge in the washing machine and scratch 2. Checking with washing about sharp tools and scratch using in the washing machine
13 WASHING EFFECT POOR 1. Improper washing 1. Train up washing team especially on bottom washing
2.Unskilled washing operator 2. Strengthen quality checkpoint in washing factory
3. Poor washing quality checkpoint 3. Will arrange a meeting with washing factory management to improve washing quality
14 SHADE OFF 1. Improper washing 1. Train up washing team especially on bottom washing
2. Unskilled washing operator 2. Strengthen quality checkpoint in washing factory
3. Denim wash performance not in up to the mark 3. Will arrange a meeting with washing factory management to improve washing quality
4. Fabrics team working to fix shading issue in fabrics stage and as well as bulk washing
15 PUCKERING 1. Incorrect machine adjustment 1. Need correction of machine adjustment
2. Tension too tight 2. Keep accurate stitch tension
3. Machine not adjusted with fabric thickness 3. Machine adjust with fabric thickness

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Sewing Defects Solve with Root Causes and Corrective Actions pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam