Defining Efficiency and Performance In terms of general definitions: Performance is the degree to which a system or machine achieves its objective. The amount of resources utilized to achieve a goal is measured by efficiency.
How to Differentiate the Efficiency and Performance in Garments Industry |Textile floor|
Defining Efficiency and Performance In terms of general definitions: Performance is the degree to which a system or machine achieves its objective. The amount of resources utilized to achieve a goal is measured by efficiency.
What is industrial engineering in the Garment Industry? │Textile Floor│
In garment manufacturing, Industrial Engineering (IE) is a functional
job that focuses on making production processes more efficient, cutting costs,
and managing workflows smoothly. It is a subfield of engineering that uses
scientific principles to increase apparel factories' productivity while
preserving quality and sustainability.
Finishing Quality Control SOP for the apparel industry
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.
How to calculate Garment SAM or SMV │Textile Floor│
Needle, Broken Needle, and Sharp Tools Control Procedure in the Apparel Industry │Textile Floor│
This procedure applies to all types of needles used in sewing machines, hand sewing, label applicator guns, staples, and other sharp tools such as knives, scissors, and cutters in the apparel industry. The article addresses the control of sharp items in two main parts: needle control and the control of other sharp tools. Needles are found in every sewing machine, so they are treated separately. In any garment industry, needles and sharp tools must be controlled individually for safety.
Sewing Quality Control Procedure in Garments Manufacturing │Textile Floor│
For every product quality is the first requirement that all customer try to find, in Garments product it is not different thing. From customer to customer, Buyers to Buyers everybody asking for maintain quality as per their required criteria. In general quality is the term that the customer asking for or customer requirement on the product. Therefore to satisfy customers' requirement production team must follow the asking standard of the product and a well-defined SOP that is Standard operating procedure must be followed to fulfill their demand on the product. So, garments product quality control is very important.
Trims and Accessories inspection procedure in Garments Store │Textile Floor│
Trims & accessories quality check is an important step in the garment manufacturing process to maintain product quality. Whether it is threads, buttons and zippers, or labels and packaging: these inevitable parts or components are necessary for the performance and look of the final product. It is crucial to have a systematic testing process to keep things up to the mark. In this blog post, we will cover the main inspection points to be considered when inspecting trims and accessories, the standard procedures, and the typical defects.
How to Cut Fabric with Relaxation & Spreading procedure in Garment Factories │Textile Floor│
Every garment company strives to develop the most effective and adaptable SOP. As the cutting section is a critical part of the garments manufacturing process, creating a detailed SOP is essential. This document serves as a simplified guide for establishing an SOP in the cutting section. Displaying the SOP prominently in the workplace helps minimize errors and improve operational efficiency.
How to Make Garment Pattern Based on Fabric Shrinkage │Textile Floor│
How to prepare the Fabric before cutting in Garment Manufacturing │Textile Floor│
Fabric Rejection Procedure to maintain Quality in Garments manufacturing │Textile Floor│
A well-established Fabric Rejection Standard Operating Procedure (SOP) is essential for ensuring consistent quality control in fabric sourcing and garment production. By defining a clear process for handling defective fabric, companies can prevent faulty materials from entering the production line, safeguarding product quality and maintaining operational efficiency. The following SOP outlines the steps for identifying, documenting, and addressing fabric defects.
Shade Band Submission and Approval Procedure in Garments Factories │Textile Floor│
Ensuring consistent color quality in garments is essential for meeting buyer specifications and maintaining brand standards. One of the most critical processes in garment manufacturing is the Shade Band Submission and Approval Procedure. This procedure ensures that the colors of fabrics and garments stay within the required shade range, preventing variations that could lead to rejection by buyers or customers.
Fabric Warehouse Management Procedure in Garment Production │Textile Floor│
In garment industry Fabric warehouse is the palce where the fabrics are received, inventoried, inspected, stored and supplied as per production plan for production. in shortly, garments warehouse serves as the hub where fabric is prepared for production that is fabric is gotten ready to its journey to be clothing.
Here the several procedures for maintaining the activities of warehouse managements because its one of the primary hub for production management.
Here the several procedures for maintaining the activities of warehouse managements because its one of the primary hub for production management.
Fabric Inspection Procedure: A Step-by-Step Guide for Quality Assurance │Textile Floor│
Fabric inspection is an important part of garment manufacturing to ensure the quality and durability of the finished product. This is a complete fabric inspection procedure that helps manufacturers detect defects early, improve product quality, and meet customer needs.
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!
TQM vs. QMS: Key Differences in Quality Management for Garments products |Textile Floor|
Ensuring best
quality with high level of its maintaining is very necessary requirement for
customer satisfaction in garments production system. The two wide & commonly
efforts for maintaining quality are QMS that is Quality Managements System and
another one is TQM that is Total quality managements Though their main
objective is same but these are two different things at the implementation
time. By focusing these two different things helps garments industries to
optimize their operations and deliver great results.
Therefore, TQM and QMS are both strategies targeted for producing high-quality,
high class products, but they varies in their main methodology. Here is a small
approach to show the main difference between these.
1. What is these actually
TQM: A management philosophy related on continuous improvement (Kaizen) across
all organizational processes, involving everyone (from High top management to
workers) to improve product quality and customer satisfaction as per their
requirements.
2. Scope
TQM: holistic and Greater. It surrounds company-wide practices, like management, human resources, supplier collaboration, and customer involvement.
QMS: Narrower in scope, often focusing on documenting and controlling processes to meet quality standards and regulatory requirements.
3. Objective
TQM: Focused on achieving customer satisfaction through continuous improvement and organizational culture.
QMS: Basically targeted to meet related asking quality by required documented procedures with the fulfill of predefined standards.
4. Actualization & Implementation
TQM: Requires cultural change, training, and active participation from all levels of employees. Emphasis is on teamwork, leadership, and quality philosophy.
QMS:
Most of the time depends on pre-arranged systematic documentation, following and specially auditing. In the implementation time most cases they follow preset work frame like ISO standards.
5. Approach & Strategies
TQM: Process-oriented, emphasizing quality improvement in every activity, including production, service, and management.
QMS: Standard-oriented, ensuring processes meet specific requirements and quality policies.
6. Focus
TQM: Broader focus on both quality and overall organizational performance. Often incorporates methodologies like Six Sigma, Kaizen, and lean manufacturing.
QMS: Centered on compliance and meeting quality assurance goals, often with specific customer or regulatory requirements in mind.
7. In Garments Manufacturing
TQM: Focuses on creating a culture of continuous improvement in production efficiency, reducing waste, improving product quality, and enhancing customer satisfaction. Examples: training workers, empowering teams, and fostering collaboration with suppliers.
QMS: Focuses on establishing and following standards such as ISO 9001 to ensure consistent product quality, on-time delivery, and regulatory compliance. Examples: setting standard operating procedures (SOPs), conducting internal audits, and maintaining inspection records.
8. Examples of Tools
TQM: Fishbone diagrams, Pareto charts, brainstorming sessions, and continuous feedback loops.
QMS: Documented procedures, checklists, audits, and records management.
Summary Table:
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.
TMU (Time Measurement Unit) and Its Application in Garment Manufacturing │Textile Floor│
What
is TMU?
TMU, or Time Measurement Unit, is a standard unit of time used to measure and
analyze work in industrial engineering. It is primarily used in methods-time
measurement (MTM) systems for assessing and standardizing manual operations.
In the Methods-Time Measurement (MTM) system, it is a small unit of time. Based
on their complexity and amount of effort required, this system gives basic
movements like reaching, grasping, or moving an object a predetermined amount
of time.
Subscribe to:
Posts ()