Practical Process of RMG Industry

Garment Defects Identified from Pre Final Inspection

Garment Defects Identified from Pre Final Inspection


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
  • 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
  • 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 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
 


Engr. Kh. Mashiur Rahman

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