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

Garments Defects Identification

Garments Defects Identification:

Garments defect is one of the curtail factors of apparel manufacturing industry because it creates a negative effect on actual productivity. If you have no idea of garments defects identification then it will be a tough job for you, but if you know it properly then it is an easy task to identify defects. So must know all types of Garments defects if you are involved with the apparel industry. It is the responsibility of the garments manufacturers to maintain a required Garments quality standard for each and every product they are offering or delivering to the buyers. After reading this article you will have the idea of all types of garments sewing defects and finishing defects. For your better understanding, I also add pictures of each type of defects. All commonly visual garments defects are included here. The quality management team will be required to train quality inspectors and quality controller by making a presentation so that they can visualize easily. I am hopeful that, this article would be helpful for any person who works in the quality department in the apparel industry.

Garments Defects Identification

How you can Identify Garments Defects

For visualizing and identifying any garments defects you need to learn about all defects with its visual characteristics first then you can simply see the product and identify defects accordingly.

List of Garments Defects Which You Can Visualize

  1. Brand Logo Mistake
  2. Broken Stitch
  3. Button Half Stitch
  4. Bartack Missing
  5. Damage
  6. Down Stitch
  7. Eyelet Hole Missing
  8. Fabric Fault
  9. Foreign Yarn
  10. Incomplete Stitch
  11. Incorrect SPI
  12. Joint Stitch
  13. Needle Cut
  14. Needle Mark
  15. Non-Functional Zipper
  16. Number Mistake
  17. Pleat Bottom Hem
  18. Puckering
  19. Raw Edge
  20. Reject
  21. Sewn Caught
  22. Shading Parts
  23. Short Stitch
  24. Skip Stitch
  25. Spot
  26. Tension Loose
  27. Un-Cut Thread
  28. Up Down Parts
  29. Velcro Missing

Here is the picture of all garments defects which we can identify visually. You may find the name of each defect at the bottom of each picture.

Bartack Missing

Bartack Missing

Brand Logo Mistake

Brand Logo Mistake

Broken Stitch

Broken Stitch

Button Half Stitch

Button Half Stitch

Damage

Defect by Damage

Eyelet Hole Missing

Eyelet Hole Missing

Down Stitch Defects of Garments

Down Stitch Defects of Garments

Fabric Fault

Fabric Fault

Foreign Yarn

Foreign Yarn

Incomplete Stitch

Incomplete Stitch

Incorrect SPI

Incorrect SPI

Joint Stitch

Joint Stitch

Needle Cut

Needle Cut

Needle Mark

Needle Mark

Non-Functional Zipper

Non-Functional Zipper

Number Mistake

Number Mistake

Pleat Bottom Hem

Pleat Bottom Hem

Puckering

Puckering

Raw Edge

Raw Edge

Reject

Reject

Sewn Caught

Sewn Caught

Shading Parts

Shading Parts

Short Stitch

Short Stitch

Skip Stitch

Skip Stitch

SPOT

SPOT

Tension Loose

Tension Loose

Un-Cut Thread

Un-Cut Thread

Up Down Parts

Up Down Parts

Velcro Missing

Velcro Missing

You also can see this article:

  1. Quality Improvement Techniques in Apparel Industry
  2. Garments quality standard
  3. Types of Garments defect

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim
E-mail: [email protected]