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

How to Take Share Buy Decision

How to Take Share Buy Decision

Share

Share is the small proportion of the capital of a company. Both private and public limited companies have share capital. But the only public limited company can issue their share in public through IPO (Initial Public Offering) to raise their share capital. Basically, the shares of the public limited company are traded in the stock market. Buyers and sellers are involved with this market through brokers (commission agent). There are thousands of millions of investors investing a large amount of money in the capital market. It is an investor’s responsibility to choose right share of a right company so that they would get a benefit (capital gain and dividend) from investing.

Question is what are the things an investor should consider before investing in the capital market through purchasing share/stock or how to take share buy decision?.

how to take share buy decision

Share/Stock Buy Decision

There are several factors/things that need to consider before investing in the capital market/stock market through purchasing share/stock of a company. These factors are:

  1. Calculate the present value of all future benefit. If the present value is more than the current price then buy the stock/share. On the other hand, if the current market price is more than the calculated present value then definitely sell the stock.
  2. To reduce the risks of investment do not forget to choose a company from a different industry. So that you can diversify your investment also make sure that you pick the right company stock
  3. Check the growth rate of the company in which you want to invest. You can get growth-related data from the annual report or in the stock market/capital market
  4. Choose stock/share which company has a lower price-earnings ratio
  5. You can also choose stock which provides higher EPS (Earnings per Share) compared with other companies
  6. If you have financial knowledge then check the financial statement (cash flow statement, income statement, balance sheet) of the companies over the period of time. Cash flow will help you to check the cash inflow and outflow. And from other financial statements, you will get profit/loss, assets & liabilities related information. It is your responsibility to check ever information that may have an impact on the future earnings of the stock/share
  7. You also need to consider the current market rate and the current economic condition of the country
  8. Never buy share without knowing anything or if anyone influences you to buy a share

These are the some of things that you can consider before investing. If you analyze properly and invest in the capital market then there will be less chance to lose your investment. Never try to gamble in the market, although many people think that buying and selling a stock is one kind of gambling.

Written by

Md. Nahian Mahmud Shaikat

Student of MBA

Institute of Business Administration (IBA)

Jahangirnagar University

Email: [email protected]

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