Garment Defects:
Defects in garment is very common word in apparel industry. Various types of garment defects are found during production process in garment factory from fabric selection to manufacturing. These defects are found in the fabric; mostly these are caused by the sewing lines. Finding defects in garment is very important task for quality controller. Because quality is strictly maintained by garment buyer. So, in the apparel industry quality control is strictly practiced right from the initial stage of sourcing raw materials to the stage of final finished garment. For textile and apparel industry product quality is measured in terms of quality and standard of fibers, yarns, fabric construction, color fastness, surface designs and the final finished garment products. By inspecting garment items before to shipping, you can be sure that any garment defects or other issues have been addressed before the goods leave the factory.
Garment Defects Analysis:
Garment defects analysis is a crucial process in the garment manufacturing industry that helps ensure quality control and improves production efficiency. By identifying, categorizing, and analyzing defects, manufacturers can address the root causes, reduce waste, and produce high-quality garments.
Importance of Garment Defects Analysis:
- Quality Improvement: Helps identify weaknesses in the production process.
- Cost Reduction: Minimizes material waste and reduces the need for rework.
- Customer Satisfaction: Ensures that only defect-free products reach consumers.
- Process Optimization: Helps in identifying issues with machine settings, material quality, or workforce skills.
Steps in Garment Defects Analysis:
- Inspection: Defects are identified during different stages such as fabric inspection, in-line inspection during sewing, and final inspection after finishing.
- Documentation: Each defect is noted and categorized with its type, location, and severity.
- Root Cause Analysis: Investigating the causes of defects to address systemic issues such as machinery, manpower, or materials.
- Corrective Action: Implementing measures to eliminate the causes of defects.
- Monitoring and Feedback: Regular review of production performance and defect recurrence.
Garment Defects may Classified in 3 Categories:
Garment defects can be categorized into several types based on the nature and location of the issues. Here are the main types of garment defects:
- Classification Based on Type of Defect
- Classification Based on Location
- Classification Based on Defect Severity
1. Classification Based on Type of Defect:
Garment defects can be categorized into several types based on the nature and location of the issues. Here are the main types of garment defects:
a. Fabric Defects:
The defects or faults are found in fabric are called fabric defects. Mostly these are not caused by the sewing lines. Running shade, selvedge to selvedge shade, holes, staining mark, missing yarn, foreign yarn, slub, hairiness etc are the common fabric defects. Fabric defects should be addressed at the point of fabric inspection, or cutting. Fabric defects should not appear at final garments. Fabric defects can further be classified into 3 groups color defects, construction defects and cleanlines.
b. Cutting Defects:
These kind of defects are found in cutting section. Wrong pattern cutting, fabric wastage due to improper cutting, cutting misaligned with fabric grain or pattern and cutting misaligned with fabric grain or pattern etc defects are found in cutting time.
c. Sewing Defects:
- Skipping Stitches: Missing stitches in seams.
- Loose Stitches: Stitches that are not tight enough.
- Uneven Stitches: Irregular stitching lengths or patterns.
- Broken Threads: Threads that break during stitching.
- Thread Puckering: Fabric gathering due to improper tension.
- Misaligned Seams: Seams that are not correctly aligned.
d. Workmanship and Handling Defects:
Such types of defects are directly caused by production section, this would include both the cutting and sewing section. Buyer’s approved samples must be referred to maintain perfect workmanship. These defects should never be allowed to raise above a certain percentage.
e. Assembly Defects:
- Mismatched Pieces: Parts of the garment (e.g., sleeves or panels) not aligning correctly.
- Incorrect Assembly: Fastenings, buttons, zippers, or other parts incorrectly attached.
- Improper Hemming: Uneven hems at the garment’s bottom.
- Wrong Placement: Pockets, zippers, or labels incorrectly positioned.
f. Trimming and Labeling Defects:
Incorrect or misplaced garment care labels, brand labels, or size labels, visible threads or excess threads not trimmed after stitching and deffective labels like labels that are improperly stitched, folded, or damaged. These types of defects are occur in this stage.
g. Fit and Size Defects: Incorrect sizing and poor shape are found that are do not fit within the size specifications.
h. Finishing Defects: Improper pressing, inconsistent hemming and untrimmed threads after stitching.
i. Packing and Shipping Defects: Creased garments, missing accessories like, buttons, belts, or other accessories intended for the garment and improper packing are occurred.
2. Classification Based on Location:
These kind of defects are found on the location of fabric defects, trims, accessories and embellishment defects on ready garment. These defects involve color and placement issues. Maximum such types of defects include color, size and placement of trims such as labels, sewing thread, screen print, embroidery designs, zipper, hangtag, lining, button and any kind of trims.
- Front and Back: Defects on the front or back of the garment, such as stains, wrinkles, or misaligned seams.
- Collar and Cuffs: Defects related to stitching, fabric, or assembly in these areas.
- Sleeves: Issues like uneven length, stitching problems, or improper sleeve attachment.
- Pockets: Problems with pocket stitching, placement, or opening.
- Zippers/Buttons: Defects that involve faulty or improperly installed closures, affecting garment functionality.
- Labeling Areas: Incorrect or missing labels that affect the garment’s brand identity or care instructions.
3. Classification Based on Defect Severity:
Garment defects are classified based on several criteria, such as their type, location, and severity. These are three types. Such as:
- Critical defects
- Major defects
- Minor defects
a. Critical Defects:
The defects present in garments lead the garments to be rejected directly are called critical defect. Such types of defects are not allowed to be shipped and those are the most serious of defects. Holes in garments, shade variation in garments fabric are the critical defects.
b. Major Defects:
The defect which is present in garments may not lead the garments be rejected rather after removing this defect garments are executed for shipment is called major defect. Those defects are not allowed over a certain percentage (3%) depending on buyers requirements. Seam puckering, broken stitches, slipped stitch are the major defects
c. Minor Defects:
The defects which are present in the garments cannot lead the garments be rejected rather if small quantity of this defect are present in the garment, garments can be accepted for shipment. Over 5% minor defects are not allowed depending on buyers requirements. This type of defect is called minor defect. Spot and sewing defect in under part is minor defect. A minor defect will usually be seen by the inspector, but may be overlooked by the customer.
Tools for Garment Defects Analysis
- Quality Control Checklists: Used by inspectors to categorize defects and ensure consistency.
- Defect Tracking Software: Programs to monitor defect data, helping identify patterns and prevent reoccurrence.
- Root Cause Analysis Tools: Techniques like the “5 Whys” or Fishbone Diagram to uncover underlying causes.
- Statistical Process Control (SPC): Using data analysis to predict defects and adjust processes before defects occur.
Conclusion
Garment defects analysis tools and classifications are help manufacturers to maintain high-quality standards, improve efficiency, and minimize waste. For maintain garment defects analysis process, it improve manufacturers production processes, enhance product quality, and also meet customer expectations.
Editor of Fashion2Apparel. She is a fashion designer and ex-lecturer in Fashion Designing. She wants to spread fashion knowledge throughout the world.
