Garment Defects Identified from Pre Final Inspection

Mashiur Rahman

1.11.15

Garment Defects:

There are different types of garments defects identified during inspection e.g. sewing defects in garments, stitching defects in garments, Stitching defects, Broken stc at any part, Skipped stc / floating, Open stc, Slip of stc, Some defects, Raw edge , Two front hi-low, Poor shape at noise/ btm, Foreign yarn, Stain mark / oil stain, Irregular width at btm, cuff rolling , Looseness inside cuff, Without bartack at pkt, hole, Body btn displaced, Half stc at btn, Broken btn, Slip of stc at side seam , Projection at cuff, collar , Pkt displaced attached , Pkt slanted attached, Two pkt hi-low etc.

Other Sewing Defects in Garments:

Pkt flap slanted attached
Glue stain mark
Iron shining mark
sewing defects in garments
Fabric off shading / various shades at SLV
Main label slanted attached
Shoulder drop uneven
Needle mark at collar, band
Rejection by snap/ metal accessories / wash
Collar point uneven
Bubble at collar
Collar band inside loose
Fraying at body front
Gathering stc at arm hole
Improper back stc at cuff, btm
Bad tension at btm stc / jam stc at slv seam
Reverse loop attached
Body btn hole broken
Two slv uneven ( for short slv)
Yoke loose Garment Defects
Pleat at side seam
Intersection point up-down
Crease mark at upper
Hiking at front upper, lower
sewing defects in garments

Presentation defects for standard and flat pack good’s

B/D Button up down (over 4 cm)
Collar spread uneven (over 1 cm)
Tie gap plus or minus (over 3 mm)
Wrong method folding size
In proper clip & pin attached
Pocket slanted
Folding side (over 1 cm)
Wrong barcode attached
Defective printed poly & paper band
Wrong tie & poly attached
sewing defects in garments
Looseness attach poly
Without punch poly
Stitching defects in garments
Wrong neck board attached
Bad looking collar pull
Skew collar
Neck button / Hole displaced
Main label shrinkage
Slanted main label / Main label bias
Improper cuff / Sleeve show
Back board show
Back tail show
Pleat near neck
Loose folding / crushed folding
Bulge at top center
Pulling near B/D button
Yoke loose
Top center & Main label not straight / Top center not straight
Micro dust / Stain mark / Oil stain
Shoulder side / Double fold at shoulder
Collar slip un even
Two fly / rever un even
Un – even rever width
Skew rever
Bad shape nose
stitching defects in garments
Over lapping collar
Folding side at back

FABRIC DEFECTS

SLUB
SPOT
SUNDRY FAULTS
FOREIGN YARN
NAPS
WEFT BAR
SHADE BAR
HOLE
CHECK MISSING
MISSING YARN
THICK YARN
KNOT
SEWING DEFECTS IN GARMENTS
WAVING FAULT

More Defects

FABRIC DEFECTS
Burn marks, holes tears
Permanent folding
Weaving and knitting defects: holes, skipped stitches, double stitches, broken stitches, foreign particles etc
CLEANLINESS
Un-washable spots and stains
Washable spots and stains
Un-cutting stitches
STITCHING AND SEAMS
SPI (stitches per inch) not respected
Unfinished stitches unless wanted
Irregular stitches unless wanted
Twisted stitches unless wanted
COLOURS
Irregular dyeing
Different shading on the same garment
HANGTAGS & LABELLING
Missing
Incomplete
Improperly fixed
Misplaced
POCKETS Garment Defects
Un symmetric left / right unless wanted
Badly cut, wrong dimensions and deformed
Wrong positioning of more than 3cm
ACCESSORIES
Zipper different from specified
Zipper defect, unable to zip / unzip
Different size than specified
Snaps pop off
Rivets /eyelets badly fixed or fall off
Quality of snaps/rivets/eyelets different than specified
IRONING
Burn marks
Shiny marks
Deformed shape/fabric
BUTTONS & BUTTONHOLES
Unlined
Not equidistant unless wanted
Broken or missing
Badly sewn or pop off
Different from specified
Badly sewn or cut buttonholes
Buttonhole too small for button
Buttonhole stitches broken or forgotten
EMBROIDERY
Thread colour and quality different from specified
Quality and quantity of stitches
PRINTING
Colour and quality different from specified
Placement different from specified
Missing print
MEASUREMENTS
Out of tolerance
Non symmetric left and right side
PACKAGING
Bad quality cartons
Wrong dimensions of cartons/polybag
Wrong carton labelling
Wrong packing (carton and polybag)

Standard Operating Procedure for Killed Garments

All the defective garments having fabric faults, washing damages, sewing damages and damaged due to improper handling, and those can not be rectified are non-confirmed goods. These are classified as Killed Garments and are sent to common platform for management review.
The garments are segregated under various categories by the respective factory Quality Manager before sending for review of Management.
During review, the management observes the causes which led the garments as killed. Accordingly, corrective steps are taken to avoid these defects.
Record is maintained to keep proper accountability of the Killed Garments.
Dedicated team is assigned to do follow up of corrective action. Management by means of reports, accesses the effectiveness of system.
After Review and accountability is done, these garments are cut into bits and disposed off.
Before disposing off the garments into bits, the labels are being taken out. Surplus and extra labels are burnt.

Standard Operating Procedures for Pre Final Inspection

The QA File containing all the information regarding the Style (including comments from Buyer and RTL Report) has to be kept ready before conducting the Pre Final Inspection. This file has to be kept ready and updated by the Merchandiser.
Pre Final Inspection has to be conducted by SSA Team/ Mini QA/ Sr. QAM.
The criteria for Pre Final inspection is mentioned below:
For Order Qty less than 5000 pcs, it is done once.
For Order Qty between 5000 pcs to 20000 pcs, it is done twice. First pre-final after completion of 30% of order qty and Second pre-final after completion of 80% of Order Qty.
For Order Qty more than 20000 pcs, it is done thrice. First pre-final after completion of 30% of order qty and Second pre-final after completion of 50% of Order Qty and Third pre-final after completion of 80% of Order Qty..
The Pre Final Inspection is conducted as per AQL 2.5 level of sampling.
The cartons offered are checked for the respective Buyer’s Shipping Mark/ ASN Sticker followed by the Carton Measurement (should fall within minimum and maximum dimensions as instructed by the Buyer).
The selected cartons are opened and the appearance of the open carton containing garments is observed (garments should not be tightly or loosely packed as it can change the presentation and appearance of the Garment Defects when the carton is opened).
The carton is checked for ratio as per Contract/ PO Sheet. The garments are checked for Shade (as per the approved Shade Band) and handfeel (as per the wash approved sample).
The Style is checked for construction by comparing with the approved Red Tag Sample. Once the styling is confirmed, the garments are checked for Quality and measurement issues as per AQL 2.5 level of inspection.
If the audit is passed, report is filed and preparations are taken for conducted the next Pre Final Inspection.
If the audit is failed, the Fail report is prepared and shown to the respective GM, Merchandising Manager and the CEO. The fail pcs are reviewed and necessary corrective action/ decision is taken immediately.
The team prepares for next Pre Final Inspection.
When all the Pre Final Inspections for a style is passed, the goods are offered to the Buyer.

Note: - a swatch card should be arranged by the physical parts of fabrics and garment defects

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