garments fault library

Prepared By: Abdul Latif (AM.QA)

2016-2017

Fault Library

Training & Development Wing Quality Assurance

2

Major Faults

Root Causes: Due to dead fibers. Fibers length is very short. Re-dying process of fabric.

DEAD COTTONFault

CategoryMajor 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.

Fault Category

Major Fault Code 312 THICK & THIN YARN

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

KNIT HOLEFault


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

KNITTING LINEFault


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

CONTAMINATIONFault


BIRD EYE

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

BIRD EYEFault


SHADED COLLARFault


FRONT BACK SHADEFault


SLEEVE SHADE VARIATIONFault


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SHADED COLLARFault


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 MARKFault


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

TINT AT HEAT TRANSFERLABEL Fault


Root Causes: Printing paper quality is not good. Low quality printing material.

OIL SPOTFault


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

DAMAGE BUTTON HOLEFault


Root Causes: Improper handling of buttons in manufacturing process. Improper handling in sewing.

PLACKET BOX SLANTFault


Root Causes: Improper cut part handling by machine operator. Low skill level of machine operator.

LABEL NOT SECUREFault


Root Causes: Improper reverse at edges of label. Negligence of inspectors or clippers.

19

PLACKET SLANTFault


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

DAMAGE LABELFault


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

DAMAGE / CRACKED LABELFault


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

NEEDLE CUTFault


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

FEED CUTFault


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

SHINE MARK AT LABELFault


Root Causes: Too much pressure of machine presser foot. Too much machine heat not as per requirement.

CROOKED COLLARFault


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

SKIP / DROP STITCHFault


Root Causes: Incorrect threading & improper clamping of needle. Compatibility of thread to fabric not correct.

BROKEN STITCHFault


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

OPEN SEAMFault


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

PLEATFault


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

PUCKERINGFault


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 SEAMFault


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

POOR REWORK

65

Fault Category

Major Fault Code 533

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

Fault Category


Root Causes: Panel width variation from cutting department. Negligence of machine operator. Extra panel cutting by machine operator.

UNEVEN SIDE SEAM

69

Fault Category


Root Causes: Side uneven cutting from cutting department. Negligence of machine operator. Extra panel cutting by machine operator.

71

RAW EDGEFault


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

73

OPERATION MISSFault


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

75

INSEAM VARIATIONFault


Root Causes: Uneven panel cutting from cutting department. Negligence of machine operator. Extra panel cutting by machine operator.

BUTTON THREAD MISSING

77

Fault Category


Root Causes: Poor quality thread & thread tension too tight. Improper lubrication or waxing & Wrong threading of machine.

79

PLACKET HIGH LOWFault


Root Causes: Improper tacking at collar attachment operation. Due to wrong button placement.

81

BUTTON ALIGNMENT OUTFault


Root Causes: Wrong button marking by machine operator. Wrong placement of buttons while attachment.

SEAM SLIP

83

Fault Category


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

TWISTED SLEEVE

85

Fault Category


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

SIDE / OUTSEAM TWISTEDFault


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

Fault Category


Root Causes: Due to cutting problem from cutting department. Due to high length wise shrinkage of fabric.

97

WAIST PLUS / MINUSFault


Root Causes: Extra machine cutting while belt making. Negligence of machine operator and size wise belt mixing in sewing.

WRONG SIZE LABEL

99

Fault Category


Root Causes: Mix size label in packet received from vendor. Mix size label provided to machine operator.

NECK WIDTH PLUS / MINUS

101

Fault Category


Root Causes: Neck width plus and minus from cutting department. Negligence & mishandling of press man while pressing the garment.

SLEEVE OPENING VARIATION

103

Fault Category


Root Causes: Length variation of cuff from cutting. Improper inspection methods.

105

CUFF OPENING VARIATIONFault


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

107

MIS-SHAPED ARMHOLEFault


Root Causes: Negligence & low skill level of machine operator. Panel cutting uneven by machine operator.

POCKET SLANT

109

Fault Category


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

BOTTOM SHAPE OUT

111

Fault Category


Root Causes: Cutting fault at mills & due to poor press. Improper feeding of fabric

NECK SHAPE OUT

113

Fault Category


Root Causes: Neck shape out or uneven neck cutting from cutting department. Improper machine cutting by machine operator.

DAMAGE NECK TAPE

119

Fault Category


Root Causes: Loose knitting of neck tape. Damage feed dogs of machine.

WRONG SIZE CARE LABEL

121

Fault Category


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

Fault Category


Root Causes: Operator pasting w/o marking center of garment. Operator's mishandling/carelessness.

125

HEAT TRANSFER LABEL SLANTFault


Root Causes: Label wrapper cutting is uneven. Machine operator handling problem while pasting the label.

129

WRONG SIZE BOTTOM RIBFault


Root Causes: Wrong size cutting of bottom rib from cutting department. Mix size induction in the sewing lines & negligence of machine operators.

ROOPING

131

Fault Category


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

135

WRONG SIZE SLEEVEFault


Root Causes: Due to extra cutting at sleeve hem operation. Sleeve length variation from cutting department.

EXPOSED PLACKET

139

Fault Category


Root Causes: Button not properly attached or placed at placket. Placket template not placed properly.

FRAME MARK AT LOGO

141

Fault Category


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 / MINUSFault


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

Fault Category


Root Causes: Uneven cutting of rib from cutting department. Low skill level of machine operation.

149

DAMAGE DRAW CORDFault


Root Causes: Draw cord manufacturing machine problem.

153

DAMAGE BUTTONFault


Root Causes: Wrong placement of button during attachment. Damage button received from vendor.

SOIL / DUST SPOT

17

Fault Category


Root Causes: Induction in burst poly bags & Quality inspector’s hands are not clean. Machines are not properly clean.

CUT HOLE

55

Fault Category


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 THREADFault


Root Causes: Extra wastage of thread during sewing. Negligence of clipper, machine operator and inspectors.

DARNING

127

Fault Category


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

PENCIL MARK

137

Fault Category


Root Causes: Mishandling of pencil, chalk mark by staff.

72

Fault Category

Major Fault Code 617 PRINTING SHADE VARIATION

89

Root Causes: Printing material not properly mixed. Material not properly cured.

145

DAMAGE / MISS PRINTINGFault


Root Causes: Material not properly cured. Quality of printing material is low.

74

Critical Faults

75

Dead BugsFault

CategoryCritical 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 methodDue to not using metal detector machine properly.Without replacement needle issued to operator.

BROKEN NEEDLEFault


INSECURE BUTTONFault

CategoryCritical (child)

Fault Code 465

Root Causes: SPI not as per requirement or standards. Machine is not properly working.

93

WRONG CONTENT LABELFault


Root Causes: Negligence of machine operator & mix label provided to machine operator. No information about label or fabric content provided.

5

LOOSE HAIRFault


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

80

Fault Category

Critical Fault Code 452 BLOOD STAIN

47

Root Causes: Sharp edges at work place. Insects at your work place.

81

495 Stones Left in Pocket after Wash (Children) Critical471 Closures with Sharp Edges (Children) Critical463 Damaged/Broken Closures (Children) Critical467 Drawstring/Cord not Tacked (Children) Critical473 Improper Placement of Drawstring (Children) Critical465 Insecure Button (Children) Critical474 Unwanted Sharp Point / Sharp Edge Critical477 Improper length of Drawstring (Children) Critical488 Minimum Neck Stretch Minus (Children) Critical468 Hand Sewn Buttons/Trims (Children) Critical487 Sharp Tool Critical478 Sharp point /Sharp edge/Staples/Pins Critical409 Improper Country of Origin Label Critical445 Missing / Incorrect Tracking Label (Children) Critical454 Missing Care Instruction Label Critical447 Missing Country of Origin Label Critical994 Wrong Fiber Content Critical

Other Critical Faults

82

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