Garments Fault Library

Prepared By: Abdul Latif (AM.QA)
2016-2017
Training & Development Wing
Quality Assurance

Root Causes:
 Due to dead fibers.
 Fibers length is very short.
 Re-dying process of fabric.
DEAD COTTON
Fault Category Major Fault Code 175

4
Root Causes:
 Low quality yarn.
 Variations in count.
 Singles in yarns, sliver or rove.
 Partial lapping in speed frame drafting roller.
 Low pressure on drafting rollers.
THICK & THIN YARN

Root Causes:
 Poor quality yarn & due to overheating of needle.
 Yarn tension too tight.
KNIT HOLE

Root Causes:
 Due to defective needle & needle too tight or loose in the slot.
 Dirty needle slot.
KNITTING LINE

Root Causes:
 Cotton not stored in a clean and proper place.
 Improper working method & environment.
CONTAMINATION

BIRD EYE
Root Causes:
 The tension variation.
 Hairiness is also the reason of this defect.
BIRD EYE

SHADED COLLAR

FRONT BACK SHADE

SLEEVE SHADE VARIATION

12
SHADED COLLAR
Root Causes In Dying Process:
 Material having dead fibers or other defective fibers.
 Material not properly desized.
 Absorbency of the fabric not proper.
 Impurities are not properly removed.
 Uneven heat treatment during dying.
 More hardness of water.
 pH of water not proper.
 Improper weight ratio of material, water, and chemicals.
 Improper material to water ratio.
 Defective instruments controlling temperature, pressure, speed
etc.
Other Causes:
 It arises due to improper cutting, bundling and numbering.
 When sequence of the fabric is not followed in sewing.
 When parts / component are mixed in sewing.
 Missing parts / components in bundling.
 Due to dying problem & PTP shade in lot.

CALENDER / COMPACTOR MARK
Root Causes:
 Poor opening of fabric roll while feeding.
 If pump pressure and reel speed in not equal.

TINT AT HEAT TRANSFERLABEL
Root Causes:
 Printing paper quality is not good.
 Low quality printing material.

OIL SPOT
Root Causes:
 Due to machine oil & due to handling.
 Due to poor house keeping & improper oil level or external lubrication.

DAMAGE BUTTON HOLE
Root Causes:
 Improper handling of buttons in manufacturing process.
 Improper handling in sewing.

PLACKET BOX SLANT
Root Causes:
 Improper cut part handling by machine operator.
 Low skill level of machine operator.

LABEL NOT SECURE
Root Causes:
 Improper reverse at edges of label.
 Negligence of inspectors or clippers.

19
PLACKET SLANT
Root Causes:
 Placket att. @mills might be improper & cutting uneven by scissor.
 Cutting uneven at shoulder & sleeve attached.

DAMAGE LABEL
Root Causes:
 Low quality of label material & Improper label inspection method.
 Improper time, temperature and pressure of machine.

DAMAGE / CRACKED LABEL
Root Causes:
 Low quality of label material & Improper label inspection method.
 Improper time, temperature and pressure of machine.

NEEDLE CUT
Root Causes:
 Harshness of fabric.
 Ensure correct type/size needles are used.

FEED CUT
Root Causes:
 Due to excessive pressure of presser foot.
 Feed dog height is improper or too high.

SHINE MARK AT LABEL
Root Causes:
 Too much pressure of machine presser foot.
 Too much machine heat not as per requirement.

CROOKED COLLAR
Root Causes:
 Improper cutting of shoulder by machine operators.
 Attachment of collar without marking.

SKIP / DROP STITCH
Root Causes:
 Incorrect threading & improper clamping of needle.
 Compatibility of thread to fabric not correct.

BROKEN STITCH
Root Causes:
 Poor quality thread & improper lubrication or waxing.
 High pilling effect & incorrect T.P.I.

OPEN SEAM
Root Causes:
 This happens due to improper handling of the parts of garments.
 Improper setting and timing between needles and looped or hooks etc.

PLEAT
Root Causes:
 Improper handling of cut parts by machine operator while feeding in machine.
 Speedy work by machine operator & inaccuracy in cutting parts.

PUCKERING
Root Causes:
 When operator pulls the fabric not properly & fabric parts are not equal in length.
 When upper & lower thread tension is tight but fabric is relaxed.

RUN OFF SEAM
Root Causes:
 Improper handling and low skill level of operator.
 Higher machine R.P.M (Round Per Minute).

POOR REWORK
65
Root Causes:
 Machine operator skill level is low.
 Negligence of machine operator.
 Trimming of thread at rework area is not proper before rework.

POUCH WIDTH VARIATION
67
Root Causes:
 Panel width variation from cutting department.
 Extra panel cutting by machine operator.

UNEVEN SIDE SEAM
69
Root Causes:
 Side uneven cutting from cutting department.

71
RAW EDGE
Root Causes:
 Machine cutter is not properly working.
 Auto trimmer machine not used for such operations.

73
OPERATION MISS
Root Causes:
 Working out of flow & extra handling & work load.
 Machine operator’s negligence and not completing all operations.

75
INSEAM VARIATION
Root Causes:
 Uneven panel cutting from cutting department.

BUTTON THREAD MISSING
77
Root Causes:
 Poor quality thread & thread tension too tight.
 Improper lubrication or waxing & Wrong threading of machine.

79
PLACKET HIGH LOW
Root Causes:
 Improper tacking at collar attachment operation.
 Due to wrong button placement.

81
BUTTON ALIGNMENT OUT
Root Causes:
 Wrong button marking by machine operator.
 Wrong placement of buttons while attachment.

SEAM SLIP
83
Root Causes:
 Negligence & poor handling of machine operator & stitch bite is thin.
 Higher machine R.P.M (Round Per Minute).

TWISTED SLEEVE
85
Root Causes:
 Machine operator is not following the sleeve notches.
 Notches missing while cutting the fabric.

SIDE / OUTSEAM TWISTED
Root Causes:
 Improper handling of front and back parts by machine operator.
 Wrong size front and back parts attachment & mixing of cut parts in bundles.

BODY LENGTH PLUS / MINUS
95
Root Causes:
 Due to cutting problem from cutting department.
 Due to high length wise shrinkage of fabric.

97
WAIST PLUS / MINUS
Root Causes:
 Extra machine cutting while belt making.
 Negligence of machine operator and size wise belt mixing in sewing.

WRONG SIZE LABEL
99
Root Causes:
 Mix size label in packet received from vendor.
 Mix size label provided to machine operator.

NECK WIDTH PLUS / MINUS
101
Root Causes:
 Neck width plus and minus from cutting department.
 Negligence & mishandling of press man while pressing the garment.

SLEEVE OPENING VARIATION
103
Root Causes:
 Length variation of cuff from cutting.
 Improper inspection methods.

105
CUFF OPENING VARIATION
Root Causes:
 Length variation of cuff from cutting.
 Improper inspection methods.
 Uneven or extra cutting by machine operator while cuff
making.

107
MIS-SHAPED ARMHOLE
Root Causes:
 Negligence & low skill level of machine operator.
 Panel cutting uneven by machine operator.

POCKET SLANT
109
Root Causes:
 Wrong marking for pocket placement.
 Machine operator handling problem while placing the pocket.

BOTTOM SHAPE OUT
111
Root Causes:
 Cutting fault at mills & due to poor press.
 Improper feeding of fabric

NECK SHAPE OUT
113
Root Causes:
 Neck shape out or uneven neck cutting from cutting department.
 Improper machine cutting by machine operator.

DAMAGE NECK TAPE
119
Root Causes:
 Loose knitting of neck tape.
 Damage feed dogs of machine.

WRONG SIZE CARE LABEL
121
Root Causes:
 Negligence of machine operator & due to wrong size ID label.
 Mix size care label received in a packet from vendor.

LABEL CENTER OUT
123
Root Causes:
 Operator pasting w/o marking center of garment.
 Operator's mishandling/carelessness.

125
HEAT TRANSFER LABEL SLANT
Root Causes:
 Label wrapper cutting is uneven.
 Machine operator handling problem while pasting the label.

129
WRONG SIZE BOTTOM RIB
Root Causes:
 Wrong size cutting of bottom rib from cutting department.
 Mix size induction in the sewing lines & negligence of machine operators.

ROOPING
131
Root Causes:
 Machine operator’s handling problem.
 Uneven cutting of panel at bottom.

135
WRONG SIZE SLEEVE
Root Causes:
 Due to extra cutting at sleeve hem operation.
 Sleeve length variation from cutting department.

EXPOSED PLACKET
139
Root Causes:
 Button not properly attached or placed at placket.
 Placket template not placed properly.

FRAME MARK AT LOGO
141
Root Causes:
 Too much pressure of machine presser foot.
 Too much machine heat not as per requirement.
 Machine bed surface is not properly even.
 Machine bed surface is too hard.

OUT SEAM PLUS / MINUS
143
Root Causes:
 Extra fabric cutting at waistband & leg hem operation.
 Uneven cutting of cut parts.
 Extra shrinkage of garment after washing.

NECK RIB HEIGHT UNEVEN
147
Root Causes:
 Uneven cutting of rib from cutting department.
 Low skill level of machine operation.

149
DAMAGE DRAW CORD
Root Causes:
 Draw cord manufacturing machine problem.

153
DAMAGE BUTTON
Root Causes:
 Wrong placement of button during attachment.
 Damage button received from vendor.

SOIL / DUST SPOT
17
Root Causes:
 Induction in burst poly bags & Quality inspector’s hands are not clean.
 Machines are not properly clean.

CUT HOLE
55
Root Causes:
 Negligence of the quality inspectors & Wrong method of handling clippers.
 Usage of sharp edge clippers instead of round edge clippers.

117
UNCUT / HANG THREAD
Root Causes:
 Extra wastage of thread during sewing.
 Negligence of clipper, machine operator and inspectors.

DARNING
127
Root Causes:
 Sharp edges of inspection tables, machine and cutters.
 Negligence of inspectors, clippers, and machine operators.

PENCIL MARK
137
Root Causes:
 Mishandling of pencil, chalk mark by staff.

72
PRINTING SHADE VARIATION
89
Root Causes:
 Printing material not properly mixed.
 Material not properly cured.

145
DAMAGE / MISS PRINTING
Root Causes:
 Material not properly cured.
 Quality of printing material is low.

75
Dead Bugs
Fault Category Critical Fault Code 459
Root Causes :
 Using eatable things in the unit
 Negligence of the staff.
 No awareness

76
Root Causes :
 Due to not following needle issue method
 Due to not using metal detector machine properly.
 Without replacement needle issued to operator.
BROKEN NEEDLE

INSECURE BUTTON
Fault Category Critical (child) Fault Code 465
Root Causes:
 SPI not as per requirement or standards.
 Machine is not properly working.

93
WRONG CONTENT LABEL
Root Causes:
 Negligence of machine operator & mix label provided to machine operator.
 No information about label or fabric content provided.

5
LOOSE HAIR
Root Causes:
 Improper cleanliness of work places.
 Workers are touching their hands with their hairs during work.

80
BLOOD STAIN
47
Root Causes:
 Sharp edges at work place.
 Insects at your work place.

81
495 Stones Left in Pocket after Wash (Children) Critical
471 Closures with Sharp Edges (Children) Critical
463 Damaged/Broken Closures (Children) Critical
467 Drawstring/Cord not Tacked (Children) Critical
473 Improper Placement of Drawstring (Children) Critical
465 Insecure Button (Children) Critical
474 Unwanted Sharp Point / Sharp Edge Critical
477 Improper length of Drawstring (Children) Critical
488 Minimum Neck Stretch Minus (Children) Critical
468 Hand Sewn Buttons/Trims (Children) Critical
487 Sharp Tool Critical
478 Sharp point /Sharp edge/Staples/Pins Critical
409 Improper Country of Origin Label Critical
445 Missing / Incorrect Tracking Label (Children) Critical
454 Missing Care Instruction Label Critical
447 Missing Country of Origin Label Critical
994 Wrong Fiber Content Critical

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