Different Types of Sewing Defects with Root Causes, CAP, And PAP | Part - 2

Introduction: There are many reasons for sewing defects. Some defects can happen to machine faults, and Some can happen from operators with fewer skills, carelessness, and many other problems. 

In this post, I discuss some new defects that also happen mostly in sewing time.

6. Needle hole: The hole which is created from the needle in the seam line during the sewing process, known as a needle hole.

Needle hole

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Needle cut/hole	Wrong neddle selection	Must be Install correct size needle immediately	Mechanics should be check correct needle size before sarting a new product sewing
	Use of faulty needle	Operator immediately change the needle after know about neddle problem	Operator have to carefully check needle after every 2 hour of sewing time

7. Sharing/puckering: The gathered fabric beside the seam line is identified as sharing or puckering defects.

Sharing/Puckering

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Sharing/Puckering	Incorrect Needle or looper thread tension	Check and adjust thread tension	Mechanics should be check all machines 2 days in a week
	Operator handling problem	Operator should be follow correct handling process	Arrange monthly training for teach on different process

8. Pleat: The folded fabric in the seam line is called a pleat defect.

Pleat

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Pleat	Operator doesn't align both layer and feed properly	Operator need proper	Mechanics should be check all machines 2 days in a week
	Operator handling problem	Operator should be follow correct handling process	Arrange monthly training for operator

9. Twisting: When the seam line becomes curved from one edge to another edge is called a twisting defect.

Twisting

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Twisting	Fabric cutting problem	Need to proper way of cutting with follow pattern cut mark and fabric grayline	Make sure proper way of fabric lay and follow marker
	Operator handeling problem	Need to proper way handling with follow cut mark	Need to train operator how to follow the cut mark

10. Part Up-Down: After sewing, two parts of the fabric are not equal in the seam edge is known as a Part up-down defect.

Part up-down

Name of Defect	Root Cause	Corrective Action Plan	Preventive Action Plan
Part up-down	Fabric cutting problem both side mark not same	Need to proper way of cutting with follow pattern side mark	Need to cut panel before sewing
	Operator handeling problem	Need to proper way handling with follow cut mark	Need to train operator how to follow the cut mark

As I mentioned earlier, many reasons may cause defects in different stages of garment production. But these 10 are most commonly occur in sewing time. We can produce quality full garments by reducing defects with this Root causes analysis, Corrective Action plan (CAP), and Preventive Action plan (PAP).