Different Types of Sewing Defects with Root Causes, CAP, And PAP | Part - 1

Introduction: Sewing is the most important part to shape a garment. The different parts of garments join together by sewing in the garments sewing section. But it is more challenging to produce a quality-full garment. To produce a quality-full garment, defects are the only things to disturb our production. 

So, when we produce garments, it needs to ensure that our garments are defect-free as well as very good quality-full. 

In this post, I am going to discuss some defects that gradually happen during sewing time;

1. Broken Stitch: During sewing time, threads are broken due to some machine setup problem and it calls Broken Stitch.

Broken Stitch

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Broken Stitch	Due to Trimming problem	Operator should carefull about Trimming	We Train up our operator about proper Trimming
	Due to thread stability problem	we have to carefully check thread stability	Alert to be check Thread Stability

Table - 1: Broken Stitch Root Causes, CAP, And PAP.

2. Skip Stitch: Due to improper needle and looper action, sometimes looper threads missed in stitch. This stitch is known as skip stitch.

Skip Stitch

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Skip Stitch	Needle Probelm	Change Needle Ramdomly After 2 Hrs	Train Up the Operator
	Due to improper machine adjust problem	Machanic properly setup to avoid skip stitch	We aware our operator about how to avoid skip stitch

Table - 2: Skip Stitch Root Causes, CAP, And PAP.

3. Uneven / Wavy Stitch: When the stitch line is not straight or properly curve, it calls uneven/wavy stitch.

Uneven/Wavy Stitch

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Uneven / Wavy Stitch	Operator careless sewing	Operator should carefull about thier sewing operation	We should train up our operator about proper sewing process

Table - 3: Uneven/wavy stitch Root Causes, CAP, And PAP.

You may read: Sewing Stitch Classification | Stitch classification according to British Standard 3870:1991 & ISO Standard 4915:1991

4. Cracked Stitch: Sometimes stitches are broken due to less elasticity in the seam line. This broken stitch calls a cracked stitch.

Cracked Stitch

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Cracked Stitch	Improper machine adjustment	Stop the machine & ensure proper machine adjustment	Mechanics must check the machine condition before strating sewing
	Due to less thread stability	Operator have to carefully check thread stability after sewing by stressing seam line	We should train up our operator how to check seam elasticity

Table - 4: Cracked stitch Root Causes, CAP, And PAP.

5. Open Seam: When two parts of the fabric are not sewing properly, an Open seam has occurred.

Open Seam

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Open Seam	Operator Handling Problem	Operator shall be work carefully	We are training our operator about how to work in a proper way
	Operator didn't follow M/C guide in properly	they will be follow the M/C guide properly and they ensure proper seam line	We are training our operator about how to proper use of machine guide

Table - 5: Open seam Root Causes, CAP, And PAP.

Defects are very common in the garments sector. You can't remove the defect permanently, but we can reduce these defects by taking some action. In every section and situation, you face new defects or problems, and as a quality engineer, you have to prevent all of these with technically.

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