Textile Engineering & Industrial Engineering Solutions | Expert Garment, Fashion & Apparel Production Strategies - Textile Floor
Garment Quality Control SOP, ALL in One │Textile Floor│
Finishing Quality Control SOP for Apparel Industry │Textile Floor│
The following Standard Operating Procedures (SOP) are recommended for finishing quality control in the apparel industry:
®
Garment
Reception:
All sewn garments should be sent to the finishing section after washing, if
required by the buyer's specifications.
Garment Meaning, Its Definition and Synonyms. What is Garment? │Textile Floor│
What is a Garment?
A garment is a piece of clothing
made from textile raw materials that is typically stitched using a sewing
machine. It is the most common term used to describe the clothes we wear to
cover and protect our bodies. Garments can range from casual wear like t-shirts
and boxer pants to formal attire like shirts and blouses.
In simpler terms, any item of clothing designed to be worn on the body is referred to as a garment. While a piece of cloth or fabric is a raw material, it only becomes a garment after it is cut, sewn, and finished into a wearable form. For example, a sheet of fabric is not a garment, but once it is tailored into a t-shirt, it becomes a garment.
50 Sewing Defects with Causes and Remedies : Enhance Quality & Productivity │Textile Floor│
In a garments
industry maintaining high level quality standard or high quality production standard
is critical but mandatory thins at production management all. Because to meet
customer satisfaction and factory standard it is must. There are verities of
defects can be take place at different steps and stages of production that can
impact the fitness, outlooks, appearance, longevity of garments.
These defects are lies in different stages of production that can in primary
level to finish level or fabric inspection to packing level. But the main
defects those we take high priority basis are in sewing stages. To address these
sewing defects expert have some effective remedies to terminate, in this
article we will discuss those with proper reasons with the remedies of those
defects.
1-10: Sewing Defects
1. Skipped Stitches
Description: Stitches are missing or skipped in the seam.
Causes:
1. Needle deflection or incorrect needle type.
2. Improper thread tension.
3. Faulty or worn-out needle.
4. Poor synchronization between needle and hook.
Remedies:
1. Use the correct needle type and replace damaged needles.
2. Check and adjust the sewing machine's hook timing and feed mechanism.
3. Match thread and needle size to fabric type.
4. Maintain consistent sewing speed.
2. Broken Stitches
Description: Stitches break during or after sewing.
Causes:
1. Weak or incompatible thread.
2. Excessive tension on the thread.
3. Poor quality of the fabric.
4. Needle damage or improper needle size.
Remedies:
1. Adjust thread tension to avoid excessive pulling.
2. Use high-quality, compatible thread for the fabric.
3. Set appropriate stitch length and density for the garment type.
4. Ensure smooth fabric feed during sewing.
3. Uneven Stitching
Description: Stitch length or alignment varies.
Causes:
1. Uneven fabric feeding.
2. Faulty feed mechanism.
3. Improper tension settings.
Remedies:
1. Regularly check and clean feed dogs and presser foot.
2. Calibrate thread tension for consistency.
3. Train operators to maintain steady speed and handle fabric evenly.
4. Loose Stitches
Description: Stitches appear loose and do not hold fabric layers together.
Causes:
1. Low thread tension.
2. Incorrect bobbin setting.
3. Poor quality thread or improper thread path.
Remedies:
1. Tighten thread tension settings appropriately.
2. Verify proper threading of both the top and bobbin threads.
3. Adjust the stitch type and density for the specific fabric.
5. Puckering
Description: Fabric gathers or wrinkles around stitches.
Causes:
1. Excessive tension on threads.
2. Incompatible needle, thread, and fabric.
3. Uneven feed or poor fabric handling.
Remedies:
1. Reduce thread tension and ensure proper fabric feeding.
2. Stabilize lightweight or stretchy fabrics before sewing.
3. Use the correct thread and needle for the fabric type.
4. Avoid pulling or stretching fabric during stitching.
6. Unbalanced Stitches
Description: Upper and lower threads are not evenly balanced.
Causes:
1. Incorrect tension adjustment.
2. Thread quality inconsistencies.
3. Misaligned bobbin or hook timing.
Remedies:
1. Balance the tension settings for top and bobbin threads.
2. Ensure the bobbin is wound evenly and use high-quality thread.
3. Service the machine to correct timing issues.
7. Thread Breakage
Description: Thread breaks frequently during sewing.
Causes:
1. Low-quality thread.
2. High thread tension.
3. Worn or damaged needle or hook.
4. Sharp edges in the thread path.
Remedies:
1. Use high-quality, fabric-appropriate thread.
2. Replace the needle with the correct size and type.
3. Reduce tension settings and smooth rough parts on the machine.
8. Incorrect Stitch Density
Description: Stitch length is too long or too short.
Causes:
1. Incorrect machine setting.
2. Uneven fabric feeding.
3. Operator error.
Remedies:
1. Set appropriate stitch length and density for the garment type.
2. Train operators to maintain steady speed and fabric feed.
3. Ensure the machine feed mechanism is calibrated and clean.
9. Improper Back Stitching
Description: Start or end of the seam is not secured properly.
Causes:
1. Operator error or skipped backstitch process.
2. Incorrect machine setup for reverse stitching.
Remedies:
1. Train operators to start and finish stitches properly with sufficient
overlap.
2. Adjust tension settings to avoid loose or tight backstitches.
3. Set stitch length in reverse to match forward stitching.
10. Needle Cuts or Needle Marks in Fabric
Description: Visible damage or punctures in the fabric from the needle.
Causes:
1. Wrong needle size or type.
2. Dull or damaged needle.
3. Sewing too close to seams or previously stitched areas.
Remedies:
1. Use the correct needle size and type (e.g., ballpoint needles for knits).
2. Minimize resewing over the same area.
3. Test sewing on fabric samples and use appropriate fabric stabilizers.
11-20: Seam Defects
11. Open Seams
Description: Seams come apart or are not properly joined.
Causes:
1. Insufficient stitch density or improper backstitching.
2. Incorrect thread tension or weak thread.
3. Poor seam construction techniques.
Remedies:
1. Increase stitch density and ensure proper backstitching at the start and end
of seams.
2. Use stronger, fabric-appropriate thread.
3. Train operators in seam joining techniques.
4. Conduct inspections for weak or improperly sewn seams.
12. Seam Puckering
Description: Seams are wrinkled or gathered along their length.
Causes:
1. Excessive thread tension or improper stitch density.
2. Mismatch of thread and needle size.
3. Fabric distortion during sewing.
Remedies:
1. Adjust thread tension and use optimal stitch density for the fabric.
2. Use thread and needle sizes suitable for the fabric weight and type.
3. Stabilize lightweight or stretchy fabrics before sewing.
4. Use differential feed for challenging fabrics.
13. Broken Seams
Description: Seams split or tear under stress.
Causes:
1. Weak thread or incorrect seam type for the garment.
2. Poor stitch quality or inadequate reinforcement.
3. Stress points not reinforced (e.g., corners or pockets).
Remedies:
1. Use high-strength thread and appropriate seam types (e.g., double-stitched
seams for stress areas).
2. Reinforce stress points with bar tacking or additional stitching.
3. Regularly inspect seam strength during production.
14. Twisted Seams
Description: Seams do not lie flat and cause garment distortion.
Causes:
1. Incorrect pattern cutting or misalignment during stitching.
2. Fabric twisting due to improper grain alignment.
3. Operator error in handling fabric during sewing.
Remedies:
1. Ensure accurate cutting and align fabric grains properly during assembly.
2. Train operators to handle fabric smoothly and maintain alignment.
3. Use seam guides or templates to assist with straight sewing.
15. Seam Slippage
Description: Fabric layers pull apart along the seam, exposing threads.
Causes:
1. Weak fabric weave or insufficient seam allowance.
2. Stitch density too low for the fabric type.
3. Using inappropriate thread or stitch types.
Remedies:
1. Increase seam allowance or use stronger seam construction techniques like
French seams.
2. Adjust stitch density to ensure secure seams.
3. Reinforce seams on weak fabrics with stay tape or interlining.
16. Uneven Seam Width
Description: Seam allowances vary in width, affecting garment appearance and durability.Causes:
1. Inconsistent operator handling during stitching.
2. Poorly marked or cut fabric pieces.
3. Lack of seam guides or templates.
Remedies:
1. Use seam guides on sewing machines for consistent width.
2. Mark seam allowances clearly on fabric before sewing.
3. Train operators to maintain consistent fabric feeding.
17. Seam Grinning
Description: Threads in the seam become visible when the fabric is stretched.
Causes:
1. Low stitch density or improper seam type.
2. Weak thread or insufficient tension.
3. Excessive stretching during sewing or wearing.
Remedies:
1. Increase stitch density for secure seams.
2. Use stretchable thread for fabrics with elasticity.
3. Choose seam types that provide more coverage, such as flat-felled seams.
18. Seam Damage
Description: Fabric tears or shows needle damage near the seam.
Causes:
1. Incorrect needle type or size.
2. Excessive stitch density or improper machine settings.
3. Poor fabric quality.
Remedies:
1. Use fabric-appropriate needles (e.g., ballpoint for knits).
2. Adjust stitch density to prevent fabric weakening.
3 .Test fabric quality and replace defective batches.
19. Overlapping Seams
Description: Multiple seams overlap unnecessarily, creating bulk and irregularity.
Causes:
1. Operator error in seam alignment.
2. Poor planning of seam intersections in garment design.
Remedies:
1. Train operators to align and join seams correctly.
2. Redesign seam intersections to reduce bulk (e.g., using flat seams).
3. Inspect seam intersections during assembly.
20. Improper Seam Alignment
Description: Seams do not align at garment intersections or panels.
Causes
1. Inaccurate cutting or marking of fabric pieces.
2. Operator error in sewing panel edges.
3. Uneven fabric feeding during stitching.
Remedies:
1. Ensure precise cutting and marking of patterns.
2. Use guides or templates for aligning seams during stitching.
3. Train operators to properly align panels and maintain straight seams.
21-30: Appearance Defects
21. Shade Variation
Description: Fabric or garment shades are inconsistent, affecting the appearance.
Causes:
1. Dye lot differences or fabric batches.
2. Exposure to light, heat, or chemicals.
3. Inconsistent fabric handling during dyeing or production.
Remedies:
1. Use fabrics from the same dye lot whenever possible.
2. Conduct shade testing before production and use proper lighting conditions.
3. Implement standardized dyeing processes to ensure consistent shade.
4. Use colorfast fabrics and check color consistency after each stage.
22. Oil Stains
Description: Oil or grease stains on fabric, usually caused by machine lubrication or handling.
Causes:
1. Machine oil leakage during operation.
2. Inadequate cleaning or oil spillage during maintenance.
3. Handling the fabric with oily hands.
Remedies:
1. Clean and maintain machinery regularly to prevent oil leakage.
2. Use oil-resistant fabrics or pre-wash fabric before processing.
3. Train workers to handle fabrics with clean hands and avoid oily areas.
4. Apply stain removal treatments on affected garments before finishing.
23. Dirty Stitches
Description: Stitches appear contaminated with dirt, dust, or oil.
Causes:
1. Lack of cleanliness in the sewing environment.
2. Use of unclean or rusty needles and sewing machines.
3. Storing or handling fabrics in dirty areas.
Remedies:
1. Maintain a clean work environment and ensure proper ventilation.
2. Regularly clean machines and needles to prevent contamination.
3. Handle fabrics with clean gloves and store them in a dust-free area.
24. Improper Top Stitching
Description: Top stitching is misaligned, uneven, or not done according to design specifications.
Causes:
1. Incorrect stitch length or thread tension.
2. Misalignment during sewing.
3. Operator error in maintaining a consistent sewing position.
Remedies:
1. Use the correct stitch length, density, and thread tension for top stitching.
2. Mark top-stitching lines clearly on the fabric.
3. Train operators to sew accurately along the marked lines.
4. Use a walking foot or guide attachment for consistent stitching.
25. Distorted Plackets
Description: Plackets (e.g., on shirts or jackets) are crooked, misaligned, or incorrectly constructed.
Causes:
1. Poor cutting or marking of fabric.
2. Inaccurate stitching or seam allowance.
3. Fabric stretching or pulling during stitching.
Remedies:
1. Cut and mark placket patterns accurately and evenly.
2. Use interfacing or stabilizers to prevent fabric distortion.
3. Ensure even tension and steady feeding while sewing plackets.
26. Irregular Pockets
Description: Pockets are misaligned, uneven, or incorrectly stitched.
Causes:
1. Inaccurate cutting or pattern alignment.
2. Operator error in pocket attachment.
3. Poorly designed pocket pattern.
Remedies:
1. Accurately align and mark pocket positions before stitching.
2. Use templates or guides for consistent pocket placement.
3. Ensure correct pocket dimensions are maintained during sewing.
4. Reinforce the pocket corners to avoid distortion.
27. Improper Labels
Description: Labels are incorrectly positioned, folded, or not securely attached.
Causes:
1. Incorrect labeling positions in the garment pattern.
2. Poor sewing techniques for attaching labels.
3 .Inaccurate folding or cutting of labels.
Remedies:
1. Ensure accurate label placement according to design specs.
2. Use proper sewing techniques for attaching labels (e.g., using a label machine or hand stitching for secure placement).
3. Double-check label orientation and size during cutting and attaching.
28. Improper Hems
Description: Hems are uneven, too wide, or improperly stitched.
Causes:
1. Misalignment during fabric folding.
2. Incorrect stitch length or tension.
3. Operator error in hem folding and sewing.
Remedies:
1. Accurately measure and fold hems to the correct width.
2. Use the appropriate stitch type (e.g., blind hem, topstitch) for the fabric and hem style.
3. Train operators to handle hem folds and ensure proper stitching without puckering.
29. Twisted Garment Panels
Description: Fabric panels are twisted, causing the garment to fit unevenly.
Causes:
1. Fabric grain misalignment during cutting.
2. Poor stitching technique causing fabric to twist.
3. Improper handling of fabric during assembly.
Remedies:
1. Ensure fabric grain lines are properly aligned during cutting.
2. Handle panels carefully and avoid stretching or twisting fabric during assembly.
3. Use accurate cutting guides and templates for fabric pieces.
30. Visible Needle Holes
Description: Small, visible puncture marks left by the needle on the fabric.
Causes:
1. Incorrect needle type or size.
2. Using the wrong stitch for delicate or fine fabrics.
3. Using old or dull needles.
Remedies:
1. Select the correct needle size and type for the fabric (e.g., ballpoint needles for knits).
2. Use a fine needle and avoid heavy stitching on delicate fabrics.
3. Change needles regularly to avoid damage to fabric.
4. Test on fabric scraps to check for needle marks before proceeding with full production.
31-40: Operational Defects
31. Improper Bar Tacking
Description: Bar tacking is incorrectly applied or not strong enough, leading to unravelling or weakening of seams.
Causes:
1. Incorrect machine settings for bar tack size and length.
2. Incorrect placement of the bar tack on the garment.
3. Low-quality thread or insufficient number of stitches.
Remedies:
1. Adjust the bar tack machine settings for correct stitch length, width, and density.
2. Position the bar tack correctly on high-stress areas like pocket openings, belt loops, and fly areas.
3. Use strong, high-quality thread and ensure enough stitching passes to reinforce the area.
4. Regularly check bar tack placement during the assembly process.
32. Improper Dart Placement
Description: Darts are incorrectly positioned or misshaped, affecting fit and garment structure.
Causes:
1. Incorrect marking of dart position or measurement.
2. Poor pattern alignment or cutting errors.
3. Improper stitching or pressing of the dart.
Remedies:
1. Accurately mark dart positions according to the pattern, ensuring correct measurement and symmetry.
2. Align pattern pieces correctly during cutting and assembly.
3. Press darts carefully to achieve the desired fit, making sure they lie flat and smooth.
33. Loose Buttons
Description: Buttons are loosely attached, causing them to fall off or become unsewn.
2. Poor pattern alignment or cutting errors.
3. Improper stitching or pressing of the dart.
Remedies:
1. Accurately mark dart positions according to the pattern, ensuring correct measurement and symmetry.
2. Align pattern pieces correctly during cutting and assembly.
3. Press darts carefully to achieve the desired fit, making sure they lie flat and smooth.
33. Loose Buttons
Description: Buttons are loosely attached, causing them to fall off or become unsewn.
Causes:
1. Incorrect sewing technique or weak thread used for attaching buttons.
2. Inadequate number of stitches used.
3. Using the wrong type of thread or needle for button attachment.
Remedies:
1. Attach buttons with sufficient thread and make multiple passes to ensure security.
2. Use the correct type of thread for button attachment (e.g., strong polyester thread).
3. Reinforce buttons at high-stress points by adding extra stitches or using a button machine.
4. Train workers on button-sewing techniques for consistency.
34. Missed Components
Description: Certain components (e.g., zippers, labels, pockets) are forgotten or overlooked during garment assembly.
1. Incorrect sewing technique or weak thread used for attaching buttons.
2. Inadequate number of stitches used.
3. Using the wrong type of thread or needle for button attachment.
Remedies:
1. Attach buttons with sufficient thread and make multiple passes to ensure security.
2. Use the correct type of thread for button attachment (e.g., strong polyester thread).
3. Reinforce buttons at high-stress points by adding extra stitches or using a button machine.
4. Train workers on button-sewing techniques for consistency.
34. Missed Components
Description: Certain components (e.g., zippers, labels, pockets) are forgotten or overlooked during garment assembly.
Causes:
1. Incomplete work instructions or assembly process.
2. Lack of a systematic approach to checking all garment parts.
3. Operator error or rush in production.
Remedies:
1. Implement a checklist to ensure all components are included during assembly.
2. Develop a systematic process with checks for each stage of garment production.
3. Inspect garments before final finishing to confirm that all components are attached.
35. Wrong Thread Color
Description: Thread color doesn’t match the garment fabric or design, affecting the garment's appearance.
1. Incomplete work instructions or assembly process.
2. Lack of a systematic approach to checking all garment parts.
3. Operator error or rush in production.
Remedies:
1. Implement a checklist to ensure all components are included during assembly.
2. Develop a systematic process with checks for each stage of garment production.
3. Inspect garments before final finishing to confirm that all components are attached.
35. Wrong Thread Color
Description: Thread color doesn’t match the garment fabric or design, affecting the garment's appearance.
Causes:
1. Incorrect thread selection based on fabric color or design specifications.
2. Miscommunication between design, production, and quality control teams.
3. Dye lot variation in thread color.
Remedies:
1. Ensure thread colors are selected according to the garment's fabric and design specifications.
2. Conduct pre-production checks to confirm thread color consistency.
3. Implement color-matching systems for both fabric and thread before starting production.
4. Regularly inspect thread color consistency from different batches.
36. Incorrect Zipper Placement
Description: Zippers are misaligned or incorrectly positioned, affecting the garment’s functionality and appearance.
1. Incorrect thread selection based on fabric color or design specifications.
2. Miscommunication between design, production, and quality control teams.
3. Dye lot variation in thread color.
Remedies:
1. Ensure thread colors are selected according to the garment's fabric and design specifications.
2. Conduct pre-production checks to confirm thread color consistency.
3. Implement color-matching systems for both fabric and thread before starting production.
4. Regularly inspect thread color consistency from different batches.
36. Incorrect Zipper Placement
Description: Zippers are misaligned or incorrectly positioned, affecting the garment’s functionality and appearance.
Causes:
1. Poor pattern marking or inaccurate cutting of fabric.
2. Incorrect operator handling or misalignment during zipper attachment.
3. Lack of proper guides or templates for zipper placement.
Remedies:
1. Mark zipper placement accurately according to the design pattern.
2. Use zipper guides or templates to ensure accurate and consistent placement.
3. Ensure proper machine settings for zipper stitching to avoid misalignment.
4. Inspect zipper alignment carefully before final sewing.
37. Improper Patch Application
Description: Patches are incorrectly positioned, stitched unevenly, or fail to adhere properly.
1. Poor pattern marking or inaccurate cutting of fabric.
2. Incorrect operator handling or misalignment during zipper attachment.
3. Lack of proper guides or templates for zipper placement.
Remedies:
1. Mark zipper placement accurately according to the design pattern.
2. Use zipper guides or templates to ensure accurate and consistent placement.
3. Ensure proper machine settings for zipper stitching to avoid misalignment.
4. Inspect zipper alignment carefully before final sewing.
37. Improper Patch Application
Description: Patches are incorrectly positioned, stitched unevenly, or fail to adhere properly.
Causes:
1. Incorrect patch placement or pattern cutting.
2. Using an improper stitching technique or inadequate thread tension.
3. Patches not adequately secured before stitching.
Remedies:
1. Accurately position and mark the patch according to design specifications.
2. Use a strong, matching thread for patch attachment and ensure proper stitch density.
3. Press and secure patches before stitching to avoid shifting.
4. Inspect patches for proper adhesion and placement during production.
1. Incorrect patch placement or pattern cutting.
2. Using an improper stitching technique or inadequate thread tension.
3. Patches not adequately secured before stitching.
Remedies:
1. Accurately position and mark the patch according to design specifications.
2. Use a strong, matching thread for patch attachment and ensure proper stitch density.
3. Press and secure patches before stitching to avoid shifting.
4. Inspect patches for proper adhesion and placement during production.
38. Untrimmed Threads
Description: Excess threads are left untrimmed on the garment, affecting its cleanliness and overall appearance.
Causes:
1. Lack of attention to finishing details.
2. Poor operator training or time constraints leading to rushed work.
3. Inadequate quality control checks at the end of production.
1. Lack of attention to finishing details.
2. Poor operator training or time constraints leading to rushed work.
3. Inadequate quality control checks at the end of production.
Remedies:
1. Implement strict finishing protocols to ensure all loose threads are trimmed.
2. Ensure workers are trained in thread trimming and handling techniques.
3. Perform a final inspection for thread trimming before garments are packed.
4. Use thread trimmers or tools designed for quick and efficient thread removal.
39. Excessive Fabric Stretching
Description: Fabric becomes stretched out of shape, causing distortion in the garment’s fit.
Causes:
1. Incorrect sewing techniques or machine settings.
2. Using inappropriate needles or thread for stretchy fabrics.
3. Excessive pulling or handling of the fabric during sewing.
Remedies:
1. Use a ballpoint or stretch needle for elastic or stretchy fabrics.
ü Adjust machine settings to minimize fabric stretch (e.g., use walking feet or differential feed).
2. Avoid pulling or stretching fabric as it’s fed through the machine.
3. Use stabilizers or fusible interfacing for added structure during assembly.
40. Improper Waistband Attachment
Description: The waistband is attached incorrectly, causing discomfort, misalignment, or poor fit.
1. Incorrect sewing techniques or machine settings.
2. Using inappropriate needles or thread for stretchy fabrics.
3. Excessive pulling or handling of the fabric during sewing.
Remedies:
1. Use a ballpoint or stretch needle for elastic or stretchy fabrics.
ü Adjust machine settings to minimize fabric stretch (e.g., use walking feet or differential feed).
2. Avoid pulling or stretching fabric as it’s fed through the machine.
3. Use stabilizers or fusible interfacing for added structure during assembly.
40. Improper Waistband Attachment
Description: The waistband is attached incorrectly, causing discomfort, misalignment, or poor fit.
Causes:
1. Inaccurate pattern marking or cutting.
2. Poor sewing technique or misalignment during waistband attachment.
3. Using an incorrect type of waistband or interfacing for the fabric.
Remedies:
1. Accurately measure and cut waistbands according to the pattern and fabric type.
2. Attach waistbands using a proper technique, ensuring even alignment and secure stitching.
3. Use appropriate interfacing or stabilizers to prevent stretching or shifting.
4. Inspect the waistband fit before final assembly and finishing.
41-50: Fabric and Structural Defects
41. Fabric Holes
Description: Holes appear in the fabric due to needle punctures, sharp objects, or mishandling.
1. Inaccurate pattern marking or cutting.
2. Poor sewing technique or misalignment during waistband attachment.
3. Using an incorrect type of waistband or interfacing for the fabric.
Remedies:
1. Accurately measure and cut waistbands according to the pattern and fabric type.
2. Attach waistbands using a proper technique, ensuring even alignment and secure stitching.
3. Use appropriate interfacing or stabilizers to prevent stretching or shifting.
4. Inspect the waistband fit before final assembly and finishing.
41-50: Fabric and Structural Defects
41. Fabric Holes
Description: Holes appear in the fabric due to needle punctures, sharp objects, or mishandling.
Causes:
® Incorrect needle size or type.
® Improper handling of fabric during cutting or stitching.
® Sharp objects or rough edges on machines.
Remedies:
ü Ensure the correct needle size and type for the fabric (e.g., use ballpoint needles for knits).
ü Avoid pulling or stretching the fabric excessively during stitching.
ü Use smooth-edged cutting tools and inspect machines for rough areas that could cause fabric damage.
ü Perform regular maintenance of machines to avoid sharp or damaged parts.
42. Fabric Fraying
Description: Fabric edges become unraveled or raw after cutting, often leading to damage in the garment.
® Incorrect needle size or type.
® Improper handling of fabric during cutting or stitching.
® Sharp objects or rough edges on machines.
Remedies:
ü Ensure the correct needle size and type for the fabric (e.g., use ballpoint needles for knits).
ü Avoid pulling or stretching the fabric excessively during stitching.
ü Use smooth-edged cutting tools and inspect machines for rough areas that could cause fabric damage.
ü Perform regular maintenance of machines to avoid sharp or damaged parts.
42. Fabric Fraying
Description: Fabric edges become unraveled or raw after cutting, often leading to damage in the garment.
Causes:
® Lack of finishing on fabric edges.
® Use of poorly finished or loosely woven fabrics.
® Inadequate seam allowances.
Remedies:
ü Finish raw fabric edges using overlocking, serging, or binding to prevent fraying.
ü Use fabrics that are less prone to fraying or apply fray-resistant treatments.
ü Ensure adequate seam allowances to allow room for finishing.
ü Consider using a fabric stabilizer or interfacing for delicate fabrics.
43. Improper Pleats
Description: Pleats are uneven, not aligned, or poorly pressed, affecting the garment's fit and appearance.
® Lack of finishing on fabric edges.
® Use of poorly finished or loosely woven fabrics.
® Inadequate seam allowances.
Remedies:
ü Finish raw fabric edges using overlocking, serging, or binding to prevent fraying.
ü Use fabrics that are less prone to fraying or apply fray-resistant treatments.
ü Ensure adequate seam allowances to allow room for finishing.
ü Consider using a fabric stabilizer or interfacing for delicate fabrics.
43. Improper Pleats
Description: Pleats are uneven, not aligned, or poorly pressed, affecting the garment's fit and appearance.
Causes:
® Incorrect pleat marking or measurement.
® Poor pressing techniques leading to misalignment.
® Incorrect fabric tension or handling during pleating.
Remedies:
ü Accurately mark and measure pleat placement on the fabric before stitching.
ü Press pleats in the correct direction using steam and a press cloth for smooth edges.
ü Use pleating guides or templates to maintain consistency in pleat size and alignment.
ü Avoid stretching fabric while pleating and ensure it feeds evenly during stitching.
44. Snags in Fabric
Description: Snags occur when threads are pulled or caught, often creating loops or damage in the fabric surface.
® Incorrect pleat marking or measurement.
® Poor pressing techniques leading to misalignment.
® Incorrect fabric tension or handling during pleating.
Remedies:
ü Accurately mark and measure pleat placement on the fabric before stitching.
ü Press pleats in the correct direction using steam and a press cloth for smooth edges.
ü Use pleating guides or templates to maintain consistency in pleat size and alignment.
ü Avoid stretching fabric while pleating and ensure it feeds evenly during stitching.
44. Snags in Fabric
Description: Snags occur when threads are pulled or caught, often creating loops or damage in the fabric surface.
Causes:
® Rough surfaces on sewing machine parts, such as the feed dogs or needle plate.
® Sharp objects in the production area or snags from machinery.
® Use of delicate fabrics with loose weaves that are prone to snagging.
Remedies:
ü Inspect and smooth all machine parts regularly to avoid rough spots.
ü Use appropriate needles and threads for delicate fabrics to reduce snagging risk.
ü Handle fabrics gently and avoid abrasive surfaces during production.
ü Consider using a finer thread and needle for delicate fabrics to minimize damage.
45. Wrinkling After Stitching
Description: Garments or fabric panels develop wrinkles or puckers after stitching, affecting the final appearance.
® Rough surfaces on sewing machine parts, such as the feed dogs or needle plate.
® Sharp objects in the production area or snags from machinery.
® Use of delicate fabrics with loose weaves that are prone to snagging.
Remedies:
ü Inspect and smooth all machine parts regularly to avoid rough spots.
ü Use appropriate needles and threads for delicate fabrics to reduce snagging risk.
ü Handle fabrics gently and avoid abrasive surfaces during production.
ü Consider using a finer thread and needle for delicate fabrics to minimize damage.
45. Wrinkling After Stitching
Description: Garments or fabric panels develop wrinkles or puckers after stitching, affecting the final appearance.
Causes:
® Incorrect tension settings on the sewing machine.
® Over handling or pulling of fabric during stitching.
® Lack of proper pressing after sewing.
Remedies:
ü Adjust machine tension to avoid fabric bunching or puckering during stitching.
ü Use appropriate stitch types and settings for the fabric to minimize tension distortion.
ü Press the garment immediately after stitching, using steam and a press cloth if necessary.
ü Avoid pulling or stretching fabric as it passes through the machine.
46. Incorrect Lining Attachment
Description: The lining is incorrectly attached to the garment, either by misalignment or improper stitching, affecting fit and appearance.
® Incorrect tension settings on the sewing machine.
® Over handling or pulling of fabric during stitching.
® Lack of proper pressing after sewing.
Remedies:
ü Adjust machine tension to avoid fabric bunching or puckering during stitching.
ü Use appropriate stitch types and settings for the fabric to minimize tension distortion.
ü Press the garment immediately after stitching, using steam and a press cloth if necessary.
ü Avoid pulling or stretching fabric as it passes through the machine.
46. Incorrect Lining Attachment
Description: The lining is incorrectly attached to the garment, either by misalignment or improper stitching, affecting fit and appearance.
Causes:
® Incorrect pattern marking or fabric alignment during attachment.
® Inadequate seam allowances or stitch type for lining attachment.
® Poor planning of lining attachment sequence during garment assembly.
Remedies:
ü Ensure accurate pattern markings and seam allowances when attaching the lining.
ü Use the correct stitch type (e.g., basting or slip-stitching) for lining attachment.
ü Attach the lining step-by-step, ensuring it is smoothly aligned with the outer fabric before stitching.
ü Test lining fit before final attachment to ensure smoothness and proper alignment.
47. Improper Sleeve Attachment
Description: Sleeves are misaligned, twisted, or poorly attached, affecting the garment's fit and comfort.
® Incorrect pattern marking or fabric alignment during attachment.
® Inadequate seam allowances or stitch type for lining attachment.
® Poor planning of lining attachment sequence during garment assembly.
Remedies:
ü Ensure accurate pattern markings and seam allowances when attaching the lining.
ü Use the correct stitch type (e.g., basting or slip-stitching) for lining attachment.
ü Attach the lining step-by-step, ensuring it is smoothly aligned with the outer fabric before stitching.
ü Test lining fit before final attachment to ensure smoothness and proper alignment.
47. Improper Sleeve Attachment
Description: Sleeves are misaligned, twisted, or poorly attached, affecting the garment's fit and comfort.
Causes:
® Incorrect sleeve pattern or cutting.
® Misalignment during sleeve attachment.
® Lack of ease or space for the sleeve cap, causing puckering or tightness.
Remedies:
ü Cut and mark sleeves accurately according to the garment pattern.
ü Attach sleeves to the body using the correct technique (e.g., easing the sleeve cap to fit the armhole).
ü Use the proper machine settings to avoid puckering or distortion when attaching sleeves.
ü Press the sleeve cap area before and after attachment to maintain smoothness.
48. Misshaped Collars
Description: Collars are misshaped or do not align properly with the rest of the garment.
® Incorrect sleeve pattern or cutting.
® Misalignment during sleeve attachment.
® Lack of ease or space for the sleeve cap, causing puckering or tightness.
Remedies:
ü Cut and mark sleeves accurately according to the garment pattern.
ü Attach sleeves to the body using the correct technique (e.g., easing the sleeve cap to fit the armhole).
ü Use the proper machine settings to avoid puckering or distortion when attaching sleeves.
ü Press the sleeve cap area before and after attachment to maintain smoothness.
48. Misshaped Collars
Description: Collars are misshaped or do not align properly with the rest of the garment.
Causes:
® Incorrect collar pattern or cutting errors.
® Poor alignment during collar attachment.
® Lack of proper interfacing or stiffening material in collar construction.
Remedies:
ü Ensure accurate collar cutting and pattern placement.
ü Attach the collar using appropriate techniques, ensuring alignment and avoiding puckers.
ü Use interfacing or collar supports to maintain collar shape and structure.
ü Press collars carefully to ensure smooth, sharp edges.
49. Unbalanced Garment
Description: The garment appears uneven, with discrepancies in balance between the front, back, or side panels.
® Incorrect collar pattern or cutting errors.
® Poor alignment during collar attachment.
® Lack of proper interfacing or stiffening material in collar construction.
Remedies:
ü Ensure accurate collar cutting and pattern placement.
ü Attach the collar using appropriate techniques, ensuring alignment and avoiding puckers.
ü Use interfacing or collar supports to maintain collar shape and structure.
ü Press collars carefully to ensure smooth, sharp edges.
49. Unbalanced Garment
Description: The garment appears uneven, with discrepancies in balance between the front, back, or side panels.
Causes:
® Uneven cutting of fabric.
® Incorrect seam allowance or stitch placement.
® Fabric distortion due to improper handling during sewing.
Remedies:
ü Ensure accurate measurements and symmetrical cutting of fabric pieces.
ü Double-check the alignment of front, back, and side panels during assembly.
ü Use fabric stabilizers or interfacing to prevent distortion of lightweight or stretchy fabrics.
ü Regularly inspect garments during production to correct any imbalances.
50. Improper Thread Trimming
Description: Excess or untrimmed threads remain after stitching, affecting the garment’s appearance and quality.
® Uneven cutting of fabric.
® Incorrect seam allowance or stitch placement.
® Fabric distortion due to improper handling during sewing.
Remedies:
ü Ensure accurate measurements and symmetrical cutting of fabric pieces.
ü Double-check the alignment of front, back, and side panels during assembly.
ü Use fabric stabilizers or interfacing to prevent distortion of lightweight or stretchy fabrics.
ü Regularly inspect garments during production to correct any imbalances.
50. Improper Thread Trimming
Description: Excess or untrimmed threads remain after stitching, affecting the garment’s appearance and quality.
Causes:
® Inconsistent finishing practices or skipped steps in production.
® Operator oversight or rushing through finishing processes.
® Inadequate trimming tools or techniques.
Remedies:
ü Ensure all threads are trimmed during the final finishing stage.
ü Use thread trimmers or shears specifically designed for clean and efficient thread removal.
ü Implement a standard procedure for trimming threads after each seam, especially in high-stress areas.
ü Conduct a final inspection to verify that all loose threads have been properly trimmed.
At Textile Floor, we are committed to helping you to improve your garment manufacturing process and produce top-quality products. By understanding common garments defects and applying effective remedies, you can minimize errors and optimize production efficiency. Keep following our blog for expert insights, practical tips, and industry trends that will empower you to overcome challenges and stay ahead in the competitive textile market. Let us be your trusted partner in achieving textile excellence, one post at a time!
® Inconsistent finishing practices or skipped steps in production.
® Operator oversight or rushing through finishing processes.
® Inadequate trimming tools or techniques.
Remedies:
ü Ensure all threads are trimmed during the final finishing stage.
ü Use thread trimmers or shears specifically designed for clean and efficient thread removal.
ü Implement a standard procedure for trimming threads after each seam, especially in high-stress areas.
ü Conduct a final inspection to verify that all loose threads have been properly trimmed.
At Textile Floor, we are committed to helping you to improve your garment manufacturing process and produce top-quality products. By understanding common garments defects and applying effective remedies, you can minimize errors and optimize production efficiency. Keep following our blog for expert insights, practical tips, and industry trends that will empower you to overcome challenges and stay ahead in the competitive textile market. Let us be your trusted partner in achieving textile excellence, one post at a time!
30 Proven Ways to Boost Productivity in Garment Manufacturing and Maximize Profit │Textile Floor│
In this new era of competitive world of garment manufacturing, enhancing productivity is not just a matter of fun or not things of luxury; it’s a necessity for completion, for sustaining in market and obviously for driving profitability. By increasing the efficiency of both labor and machinery, factories can significantly reduce production costs and boost profit margins.
Style Changeover Time (COT) in Garment Manufacturing │Textile Floor│
Style
change over time (COT) or commonly named Style changing time in the production
line is an important term for production floor in the garments industry. It is
the time of setting all the required machine & equipment with technical
support of new style. Basically the term is the period between the last outputs
of the previous style to first output of the new style. So therefore this is
the time gap when the new setup for new style is done. This period needs to
minimize as possible as less because this time is one kind of wastes. Here IE
team worked closely with other supporting team. Actually the task begins
earlier from the schedule taken from production planning & control team.
In
this article, we will explain why minimizing COT is important, reasons behind
high change over time & how to make Zero the change over time.
What
is Style Changeover Time (COT) actually?
COT is the period
or time gap from the last pcs output of an old style to the first pcs output of
the newly setup style of a garments production line. It involves with various
activities like_ changing machine setup or installment, adjusting tools,
preparing man-machine-materials, and ensuring quality standards aa per required
criteria. This time is critical because every minute of downtime means lost
productivity because the minutes can impact as delays in meeting delivery
deadlines.
In ideal
conditions, Style Changeover Time should be measured in single digits
(minutes), but in many garment manufacturing setups, it stretches to hours,
affecting the overall efficiency of the production process.
Why
Reducing Style Changeover Time is very important in garments industry
Minimizing COT
leads huge benefits to garments manufacturers:
Production
Capacity Enhancement:
Reducing COT means less downtime, allowing machines to produce more units in
the same amount of time.
Improve
Line Efficiency:
Faster changeovers enhance overall line efficiency, helping manufacturers meet
tight deadlines and increase throughput.
Save
on Costs:
Minimizing COT reduces manpower costs, inventory costs, and other expenses
related to downtime and inefficiency.
Enhance
Customer Satisfaction:
On-time deliveries are crucial for customer satisfaction. A quicker changeover
time ensures that orders are completed and shipped on time, leading to repeat
business.
Boost Business Competitiveness: Faster production cycles give manufacturers a competitive edge, enabling them to meet market demands more effectively.
Reasons Behind High Style Changeover Time
Before implementing strategies to reduce COT, it’s essential to understand the factors that contribute to its increase. Here are the most common reasons for high Style Changeover Time in garment manufacturing:
1. Lack of
Multi-skilled Operators
2. Unavailability of
Cut Panels or cut part input
3. Unnecessary
Movement and Poor Workstation Layout
4. Unavailability
of Specialized Machines or Attachments
5. Quality Control
Issues
6. Work-in-Progress
(WIP) from Previous Style
7. Lack of Proper
Pre-planning
8. Unplanned Changes
in the Production Schedule
9. Operator
Training During Changeover
10. Inadequate
Communication between Teams
11. Incorrect or
Missing Information in Style Changeover Plans
12. Prolonged machine setup time, including
adjustments and calibration
13. Lack of
Required Tools and Materials at the workstations
14. Poorly Balanced Production Lines
15. Lack of Spare
Parts or Machine Maintenance
16. Not Using Lean
Manufacturing Principles like SMED (Single Minute Exchange of Dies)
17. Lack of
Standardized Procedures for Style Changeovers
18. Behavior or
attitude of middle management
19. Sudden and
unexpected plan change
20. Product &
Raw Material Diversity
21. Pre-production
activities not fulfill within time
22. Initial product
quality setting and technical support longer.
Key Activities for
Achieving Zero Change-Over Time (ZCO) in Production: Action Plan, Methodology, and
Best Practices:
1.
Timely Operator and Helper Attendance
Ensure all
operators and helpers are present on the production floor by early at start up
time, with production starting promptly to meet first-hour targets.
Action: Implement an attendance sheet
and monitor punctuality.
Responsible
Departments:
Industrial Engineering (IE), Production, Administration.
2.
Optimal Manpower Allocation
Recruit experienced
operators who align with the production line's efficiency requirements. Ensure
that operators and helpers are assigned appropriate roles to avoid skill
wastage.
Action: No helpers should work as
operators and vice versa to maintain quality and efficiency.
Responsible
Departments: IE,
Production.
3.
Preparation for Upcoming Production Styles
Ensure all
materials, including approved samples, trims cards, and production files, are
prepared in advance for new production styles.
Action: Finalize style preparations
before the scheduled input date to avoid delays.
Responsible
Departments: IE,
Production, Quality.
4.
Create Operation Bulletins (OB)
Once style data is
confirmed, the IE and planning teams should develop detailed Operation
Bulletins to guide production.
Action: Ensure OBs are ready to streamline
the production process.
Responsible
Departments: IE,
Planning.
5.
Cross-Departmental Layout Planning
Conduct team
discussions involving production, technical, and quality teams to address
potential challenges related to new styles and ensure smooth line integration.
Action: Collaborate early to anticipate
and solve issues.
Responsible
Departments: IE,
Production, Technical, Quality.
6.
Critical Operation Management
Identify critical
operations early in the process and assign qualified operators. Provide
necessary training, including cross-training, if required.
Action: Schedule overtime for
cross-training to build a versatile workforce.
Responsible
Departments: IE,
Production, Quality.
7.
Machine Preparation
Ensure that all
machines required for production are set up and tested at least one day before
production starts.
Action: Verify machine functionality
before deployment to avoid disruptions during production.
Responsible
Department: IE.
8.
Equipment Readiness
Ensure that all
essential equipment such as folders, guides, presser feet, and patterns are available
and fully functional.
Action: Coordinate with the maintenance
team to prepare the equipment.
Responsible
Departments: IE,
Production.
9.
Pre-Production Meeting (PP meeting)
Conduct a
Pre-Production Meeting to review and finalize all critical production aspects,
ensuring alignment across departments.
Action: Address potential issues
proactively to streamline production and reduce delays.
Responsible
Departments: IE,
Production, Technical, Quality, Store.
10.
Ensuring Accessories and Trims Availability
Following the
Pre-Production Meeting, confirm that all accessories and trims are available
in-house before production begins.
Action: Resolve any inventory or supply
issues promptly.
Responsible
Departments: IE,
Production, Technical, Quality, Store.
11.
Pre-Production Cut Kit Preparation
Ensure that all cut
panels are inspected and ready for feeding into the production line.
Action: Confirm that the cut kit is
accurately sized and quality-checked before production starts.
Responsible
Departments: IE,
Production, Quality.
12.
Optimized Line Layout
After reviewing
past production data, design the best possible line layout for the upcoming
production run.
Action: Apply a layout that minimizes
movement, reduces cycle time, and improves overall efficiency.
Responsible
Departments: IE,
Production.
13.
Manpower Allocation Based on Operation Bulletin (OB)
Ensure that the
required number of operators and helpers are allocated based on the OB
specifications.
Action: Address any manpower gaps or
skill mismatches before production starts.
Responsible
Departments: IE,
Production.
14.
Minimizing Line Layout Time
During layout
setup, monitor machine configurations, process timing, and quality checks to minimize
the time spent on setup.
Action: Continuously track time spent in
setup phases to identify areas for improvement.
Responsible
Departments: IE,
Production.
15.
Ensuring Method Consistency
Implement
standardized methods for critical processes to ensure consistency and minimize
errors.
Action: Follow method studies to
identify process improvements and optimize efficiency.
Responsible
Departments: IE,
Technical.
16.
Workstation & Line Balancing
Conduct thorough
work studies and monitor hourly production data to ensure line balance and
prevent workflow disruptions.
Action: Identify and resolve bottlenecks
on the floor to ensure smooth operation.
Responsible
Department: IE.
17.
Setting Operator Targets
Pre-define and
communicate individual operator targets to ensure alignment with overall
production goals.
Action: Adjust targets as necessary
during line setup to accommodate operational changes.
Responsible
Departments: IE,
Production.
18.
Addressing Bottlenecks
Identify
bottlenecks in the production process and implement corrective actions like
motion studies, time studies, and machine adjustments (e.g., motor RPM and
pulley settings).
Action: Remove obstacles to
optimize line speed and efficiency.
Responsible
Departments: IE,
Production.
19.
Learning Curve and Incentive Programs
Introduce a
learning curve for newly set-up production lines, offering incentives for
performance improvements.
Action: Track performance
milestones and reward team efforts to encourage continuous improvement.
Responsible
Departments: IE,
Production.
20.
Input Monitoring and Continuous Feeding
Ensure that
materials from cutting and stores are consistently fed into the production line
without interruptions.
Action: Monitor input flow to
maintain production continuity.
Responsible
Departments: Cutting,
Planning.
21.
Inline Quality Inspection
Implement regular
quality checks at key stages of production, particularly at needle points, to
maintain product quality.
Action: Address quality issues
immediately to prevent defects from progressing down the line.
Responsible
Department: Quality
Assurance.
22.
Promoting Team Awareness
Encourage the
production team to take proactive steps in areas like absenteeism management,
line targets, and quality improvements.
Action: Foster a collaborative
environment through regular team meetings and motivational initiatives.
Responsible Departments: Production, Quality.
Therefore
in summery, the benefits of Reducing Style Changeover Time (COT)
Increased
Productivity: Faster
changeovers result in more production output in the same amount of time.
Improved
Line Efficiency: With
reduced downtime, the production line operates at a higher efficiency,
increasing overall output.
Cost
Savings:
Minimizing changeover time reduces labor costs and overhead, leading to more
cost-effective production.
On-Time
Delivery: Faster
changeovers allow for quicker completion of orders, ensuring timely delivery to
customers.
Enhanced
Customer Satisfaction: Meeting
deadlines consistently improves customer trust and leads to repeat business.
Higher Competitiveness: By reducing COT, manufacturers can meet customer demands more effectively, improving their competitiveness in the market.
Conclusion
Reducing Style
Changeover Time (COT) is a crucial factor for improving productivity,
efficiency, and overall performance in garment manufacturing. By implementing
strategies such as pre-planning, training multi-skilled operators, optimizing
the use of tools and materials, and applying the SMED methodology,
manufacturers can streamline their changeover processes and reap the benefits
of increased output and reduced costs. Ultimately, reducing COT not only
improves the bottom line but also enhances customer satisfaction and
strengthens a company’s competitive edge in the marketplace.
How to Set Daily Production Targets Using SAM vs. Cycle Time in Apparel Manufacturing │Textile Floor│
To set production target at daily production floor in garments industry, Standard Allowed Minutes (SAM) and Cycle Time both are necessarily used by production management team. Though it is depends on several factors but SAM or Cycle time are mainly used to calculate the Targets. Calculating and establishing correct production target is an important factor to drive productions because
How to calculate the Fabric Consumption for a Trouser │Textile Floor│
In the clothing and fashion industry calculation of correct fabric consumption is very important for proper fabric utilization, cost reduction, fabric wastes control and also for proper production scheduling or planning. Especially in a knit garments its very sincerely related to understand the fabric requirements for maintaining production operations.
Therefore we search, study and derive a short effective calculations way that is how to calculate Fabric consumption for a Trouser.
Therefore we search, study and derive a short effective calculations way that is how to calculate Fabric consumption for a Trouser.
Garments Production Planning, Control, Challenges... │Textile Floor│
In garments manufacturing production planning and control is very important term of application that deals to utilize limited resources in order to increase productivity. In general Production planning and control works to produce and deliver quality goods in required quantities within a specific time by maintaining maximum inventory levels & flexibility during manufacturing.
How to Calculate Fabric Consumption for A Pant |Textile Floor|
Therefore we search, study and derive a short effective calculation way that is how to calculate Fabric Consumption for a Pant. So Lets discuss the overall calculation system_
Textile general knowledge for Garments Manufacturing Technology │Textile Floor│
1. What is clothing?
Ans. Clothing is one of the three basic needs of
human being. Clothing is used for covering human body or other bodies to
fulfill or satisfy the
Garments Sewing Defects and some other defects in garments │Textile Floor│
Garments pattern deffect, Fabric spreading defect in garments, Cutting defects, Color defects in garments, Sewing Defects in garments, Washing Defects in garments....
Fabric consumption formula for T-shirt │Textile Floor│
For making garments we musy know about how much fabric is required to produce. besides proper required fabric calculation will save from loss. So only efficient consumption can be the reason of cost saving at a great amount. Here below discuss about how to calculate the required fabric for T-shirt making...
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