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Prepared By: Abdul Latif (AM.QA)
Cell # +92 312-7274200
Faisalabad
Pakistan
22-09-2016
2016-2017
Quality Assurance
Trainin...
Root Causes:
 Due to dead fibers.
 Fibers length is very short.
 Re-dying process of fabric.
DEAD COTTON
Fault Category...
Root Causes:
 Re-dying process of fabric.
Fault Category Major Fault Code 391
PILLING
Root Causes:
 Low quality yarn.
 Variations in count.
 Singles in yarns, sliver or rove.
 Partial lapping in speed fra...
Root Causes:
 Low quality yarn.
 Variations in count.
Fault Category Major Fault Code 312
THICK & THIN YARN
Root Causes:
 Manual picking of cotton seeds, stones, hairs, plastic material etc.
 Spinning area is not neat and clean....
Root Causes:
 Breakage of yarn during knitting process.
Fault Category Major Fault Code 361
MISSING YARN
Root Causes:
 Lack of adequate fiber control in the drafting zone.
Fault Category Major Fault Code 308
SLUB
Root Causes:
 Knitting machine problem & breakage of yarn during knitting process.
Fault Category Major Fault Code 331
PR...
Root Causes:
 Due to rusty equipment.
Fault Category Major Fault Code 315
RUST MAKR
Root Causes:
 Breakage of lycra yarn during knitting process.
Fault Category Major Fault Code 392
LYCRA SHORT
Fault Category Major Fault Code 354
KNITTING LINE
Root Causes:
 Due to defective needle & needle too tight or loose in th...
Root Causes:
 Cotton not stored in a clean and proper place.
 Improper working method & environment.
Fault Category Majo...
Root Causes:
 Poor quality yarn & due to overheating of needle.
 Yarn tension too tight.
Fault Category Major Fault Code...
Root Causes:
 The tension variation.
 Hairiness is also the reason of this defect.
Fault Category Major Fault Code 303
B...
Fault Category Major Fault Code 340
SHADED COLLAR
Fault Category Major Fault Code 415
FRONT BACK SHADE
Fault Category Major Fault Code 617
SLEEVE SHADE VARIATION
Fault Category Major Fault Code 340
SIDE VENT TAPE SHADE
Root Causes In Dying Process:
 Material having dead fibers or other defective fibers.
 Material not properly desized.
 ...
Fault Category Major Fault Code 313
CALENDER / COMPACTOR MARK
Root Causes:
 Poor opening of fabric roll while feeding.
 ...
Root Causes:
 Printing paper quality is not good.
 Low quality printing material.
Fault Category Major Fault Code 125
TI...
Root Causes:
 Improper handling of buttons in manufacturing process.
 Improper handling in sewing.
Fault Category Major ...
Root Causes:
 Improper cut part handling by machine operator.
 Low skill level of machine operator.
Fault Category Major...
Root Causes:
 Improper reverse at edges of label.
 Negligence of inspectors or clippers.
Fault Category Major Fault Code...
Root Causes:
 Loppers threads are too tight.
Fault Category Major Fault Code 800
PIPING
Root Causes:
 Placket att. @mills might be improper & cutting uneven by scissor.
 Cutting uneven at shoulder & sleeve at...
Root Causes:
 Low quality of label material & Improper label inspection method.
 Improper time, temperature and pressure...
Root Causes:
 Harshness of fabric.
 Ensure correct type/size needles are used.
Fault Category Major Fault Code 401
NEEDL...
Root Causes:
 Due to excessive pressure of presser foot.
 Feed dog height is improper or too high.
Fault Category Major ...
Root Causes:
 Too much pressure of machine presser foot.
 Too much machine heat not as per requirement.
Fault Category M...
Root Causes:
 Improper cutting of shoulder by machine operators.
 Attachment of collar without marking.
Fault Category M...
Root Causes:
 Incorrect threading & improper clamping of needle.
 Compatibility of thread to fabric not correct.
Fault C...
Fault Category Major Fault Code 317
OIL SPOT
Root Causes:
 Due to machine oil & due to handling.
 Due to poor house keep...
Root Causes:
 This happens due to improper handling of the parts of garments.
 Improper setting and timing between needl...
Root Causes:
 Improper handling of cut parts by machine operator while feeding in machine.
 Speedy work by machine opera...
Root Causes:
 When operator pulls the fabric not properly & fabric parts are not equal in length.
 When upper & lower th...
Root Causes:
 Improper handling and low skill level of operator.
 Higher machine R.P.M (Round Per Minute).
Fault Categor...
Root Causes:
 Machine operator skill level is low.
 Negligence of machine operator.
 Trimming of thread at rework area ...
Root Causes:
 Panel width variation from cutting department.
 Negligence of machine operator.
 Extra panel cutting by m...
Fault Category Major Fault Code 505
BROKEN STITCH
Root Causes:
 Poor quality thread & improper lubrication or waxing.
 H...
Root Causes:
 Machine cutter is not properly working.
 Auto trimmer machine not used for such operations.
Fault Category...
Root Causes:
 Working out of flow & extra handling & work load.
 Machine operator’s negligence and not completing all op...
Root Causes:
 Uneven panel cutting from cutting department.
 Negligence of machine operator.
 Extra panel cutting by ma...
Root Causes:
 Poor quality thread & thread tension too tight.
 Improper lubrication or waxing & Wrong threading of machi...
Root Causes:
 Improper tacking at collar attachment operation.
 Due to wrong button placement.
Fault Category Major Faul...
Root Causes:
 Wrong button marking by machine operator.
 Wrong placement of buttons while attachment.
Fault Category Maj...
Root Causes:
 Negligence & poor handling of machine operator & stitch bite is thin.
 Higher machine R.P.M (Round Per Min...
Root Causes:
 Improper handling of front and back parts by machine operator.
 Wrong size front and back parts attachment...
Root Causes:
 Due to cutting problem from cutting department.
 Due to high length wise shrinkage of fabric.
Fault Catego...
Root Causes:
 Extra machine cutting while belt making.
 Negligence of machine operator and size wise belt mixing in sewi...
Root Causes:
 Mix size label in packet received from vendor.
 Mix size label provided to machine operator.
Fault Categor...
Root Causes:
 Neck width plus and minus from cutting department.
 Negligence & mishandling of press man while pressing t...
Root Causes:
 Length variation of cuff from cutting.
 Improper inspection methods.
Fault Category Major Fault Code 750
S...
Root Causes:
 Length variation of cuff from cutting.
 Improper inspection methods.
 Uneven or extra cutting by machine ...
Root Causes:
 Negligence & low skill level of machine operator.
 Panel cutting uneven by machine operator.
Fault Categor...
Root Causes:
 Wrong marking for pocket placement.
 Machine operator handling problem while placing the pocket.
Fault Cat...
Root Causes:
 Cutting fault at mills & due to poor press.
 Improper feeding of fabric.
Fault Category Major Fault Code 8...
Root Causes:
 Neck shape out or uneven neck cutting from cutting department.
 Improper machine cutting by machine operat...
Fault Category Major Fault Code 806
DAMAGE NECK TAPE
Root Causes:
 Loose knitting of neck tape.
 Damage feed dogs of mac...
Root Causes:
 Negligence of machine operator & due to wrong size ID label.
 Mix size care label received in a packet fro...
Root Causes:
 Operator pasting w/o marking center of garment.
 Operator's mishandling/carelessness.
Fault Category Major...
Root Causes:
 Label wrapper cutting is uneven.
 Machine operator handling problem while pasting the label.
Fault Categor...
Root Causes:
 Wrong size cutting of bottom rib from cutting department.
 Mix size induction in the sewing lines & neglig...
Root Causes:
 Machine operator’s handling problem.
 Uneven cutting of panel at bottom.
Fault Category Major Fault Code 8...
Root Causes:
 Improper thread tension of loopers.
 Thread tensionors are not working properly.
Fault Category Major Faul...
Root Causes:
 Due to extra cutting at sleeve hem operation.
 Sleeve length variation from cutting department.
Fault Cate...
Root Causes:
 Button not properly attached or placed at placket.
 Placket template not placed properly.
Fault Category M...
FRAME MARK AT LOGO
Fault Category Major Fault Code 863
Root Causes:
 Too much pressure of machine presser foot.
 Too muc...
Root Causes:
 Extra fabric cutting at waistband & leg hem operation.
 Uneven cutting of cut parts.
 Extra shrinkage of ...
Root Causes:
 Uneven cutting of rib from cutting department.
 Low skill level of machine operation.
Fault Category Major...
Fault Category Major Fault Code 992
DAMAGE DRAW CORD
Root Causes:
 Draw cord manufacturing machine problem.
Root Causes:
 Wrong placement of button during attachment.
 Damage button received from vendor.
Fault Category Major Fau...
Root Causes:
 Induction in burst poly bags & Quality inspector’s hands are not clean.
 Machines are not properly clean.
...
Root Causes:
 Negligence of machine operator.
Fault Category Major Fault Code 508
REVERSE LABEL ATTACH
Root Causes:
 Mishandling of pencil, chalk mark by staff.
Fault Category Major Fault Code 857
PENCIL MARK
Root Causes:
 Sharp edges of inspection tables, machine and cutters.
 Negligence of inspectors, clippers, and machine op...
Root Causes:
 Negligence of the quality inspectors & Wrong method of handling clippers.
 Usage of sharp edge clippers in...
Root Causes:
 Extra wastage of thread during sewing.
 Negligence of clipper, machine operator and inspectors.
Fault Cate...
Root Causes:
 Negligence of R&I supervisor, machine operator & quality staff.
 No information available in PPC file rega...
Fault Category Major Fault Code 759
MIS-SHAPED ARMHOLE
Root Causes:
 Negligence & low skill level of machine operator.
 ...
Root Causes:
 Wrong marking for pocket placement.
 Machine operator handling problem while placing the pocket.
Fault Cat...
Fault Category Major Fault Code 801
BOTTOM SHAPE OUT
Root Causes:
 Cutting fault at mills & due to poor press.
 Improper...
Root Causes:
 Wrong issuance of label from store, negligence of R&I supervisor, operator.
 Mixing in label box.
Fault Ca...
Root Causes:
 Low quality pasting material.
 Machine pressure, temperature and time is not as per requirement.
Fault Cat...
Root Causes:
 Machine pressure is not as it should be.
 Improper handling of parts.
Fault Category Major Fault Code 466
...
Root Causes:
 Uneven cutting from cutting department.
 Machine operator handling problem.
Fault Category Major Fault Cod...
Root Causes:
 Uneven cutting from cutting department.
 Machine operator handling problem.
Fault Category Major Fault Cod...
Root Causes:
 Uneven cutting from cutting department.
 Machine operator handling problem.
Fault Category Major Fault Cod...
Root Causes:
 Machine operator handling problem.
 Stripes not locked while cutting in cutting department.
Fault Category...
Root Causes:
 Uneven cutting from cutting department.
 Machine operator handling problem & extra parts cutting due to ma...
Root Causes:
 Printing material not properly mixed.
 Material not properly cured.
Fault Category Major Fault Code 617
PR...
Root Causes:
 Material not properly cured.
 Quality of printing material is low.
Fault Category Major Fault Code 929
DAM...
Root Causes:
 Improper handling of machine operator.
Fault Category Major Fault Code 995
LOOP DAMAGE
Root Causes:
 Improper handling of machine operator.
 Label wrapper cutting is not proper from edges.
Fault Category Maj...
Root Causes:
 Machine operator is not following the sleeve notches.
 Notches missing while cutting the fabric.
Fault Cat...
Root Causes:
 Machine operator handling is not proper.
Fault Category Major Fault Code 538
UNEVEN SEAM AT WAISTBAND
Root Causes:
 Handling problem while making elastic ring.
Fault Category Major Fault Code 552
DAMAGED ELASTIC
Root Causes:
 Wrong placement of frame while embroidery of logo.
Fault Category Major Fault Code 516
EMBRIDERY SEWN INTO ...
Root Causes:
 Wrong placement of frame while printing.
Fault Category Major Fault Code 516
PRINTING SEWN INTO SEAM
Fault Category Major Fault Code 824
DARNING
Root Causes:
 Sharp edges of inspection tables, machine and cutters.
 Neglig...
Root Causes:
 Improper secure & operation miss.
Fault Category Major Fault Code 995
DRAW CORD TIP MISS
Root Causes:
 Low quality thread or machine problem.
Fault Category Major Fault Code 995
DAMAGE EMBRIODERY
Root Causes:
 Improper handling of machine operator while placing the pocket.
 Improper marking for pockets.
Fault Categ...
Root Causes:
 Wrong placement of label by machine operator while pasting it.
 Improper machine cutting by machine operat...
Root Causes:
 Wrong issuance of thread from store, negligence of R&I supervisor, operator.
 No information in PPC file a...
Root Causes:
 Negligence of final inspector and packer.
 Final inspector is not inspecting the garment from inside.
Faul...
Root Causes :
 Using eatable things in the unit
 Negligence of the staff
 No awareness
Fault Category Critical Fault Co...
Root Causes :
 Due to not following needle issue method
 Due to not using metal detector machine properly.
 Without rep...
Root Causes:
 SPI not as per requirement or standards.
 Machine is not properly working.
Fault Category Critical (Child)...
Root Causes:
 Improper cleanliness of work places.
 Workers are touching their hands with their hairs during work.
Fault...
Root Causes:
 Sharp edges at work place.
 Insects at your work place.
Fault Category Critical Fault Code 452
BLOOD STAIN
Root Causes:
 Negligence of machine operator & mix label provided to machine operator.
 No information about label or fa...
495 Stones Left in Pocket after Wash (Children) Critical
471 Closures with Sharp Edges (Children) Critical
463 Damaged/Bro...
Root Causes:
 Negligence of packer.
Fault Category Major Fault Code 218
OCR STICKER MISS
Root Causes:
 Negligence of packer.
Fault Category Major Fault Code 652
WRONG SIZE GARMENT IN PACK
Root Causes:
 Negligence of packer.
Fault Category Major Fault Code 686
WRONG ASSORTMENT
Root Causes:
 Negligence of packer.
Fault Category Major Fault Code 217
WRONG SIZE UPC STICKER
Fault Library 2016-2017 By Abdul Latif (+92 3127274200)
Fault Library 2016-2017 By Abdul Latif (+92 3127274200)
Fault Library 2016-2017 By Abdul Latif (+92 3127274200)
Fault Library 2016-2017 By Abdul Latif (+92 3127274200)
Fault Library 2016-2017 By Abdul Latif (+92 3127274200)
Fault Library 2016-2017 By Abdul Latif (+92 3127274200)
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Fault Library 2016-2017 By Abdul Latif (+92 3127274200)

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This fault library will help to give awareness about faults and root causes & its corrective action to quality inspectors who are working in garment manufacturing industry.

Published in: Education
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Fault Library 2016-2017 By Abdul Latif (+92 3127274200)

  1. 1. Prepared By: Abdul Latif (AM.QA) Cell # +92 312-7274200 Faisalabad Pakistan 22-09-2016 2016-2017 Quality Assurance Training & Development Wing
  2. 2. Root Causes:  Due to dead fibers.  Fibers length is very short.  Re-dying process of fabric. DEAD COTTON Fault Category Major Fault Code 175
  3. 3. Root Causes:  Re-dying process of fabric. Fault Category Major Fault Code 391 PILLING
  4. 4. Root Causes:  Low quality yarn.  Variations in count.  Singles in yarns, sliver or rove.  Partial lapping in speed frame drafting roller.  Low pressure on drafting rollers. Fault Category Major Fault Code 849 YARN VARIATION
  5. 5. Root Causes:  Low quality yarn.  Variations in count. Fault Category Major Fault Code 312 THICK & THIN YARN
  6. 6. Root Causes:  Manual picking of cotton seeds, stones, hairs, plastic material etc.  Spinning area is not neat and clean. Fault Category Major Fault Code 311 CONTAMINATED YARN
  7. 7. Root Causes:  Breakage of yarn during knitting process. Fault Category Major Fault Code 361 MISSING YARN
  8. 8. Root Causes:  Lack of adequate fiber control in the drafting zone. Fault Category Major Fault Code 308 SLUB
  9. 9. Root Causes:  Knitting machine problem & breakage of yarn during knitting process. Fault Category Major Fault Code 331 PRESS OFF
  10. 10. Root Causes:  Due to rusty equipment. Fault Category Major Fault Code 315 RUST MAKR
  11. 11. Root Causes:  Breakage of lycra yarn during knitting process. Fault Category Major Fault Code 392 LYCRA SHORT
  12. 12. Fault Category Major Fault Code 354 KNITTING LINE Root Causes:  Due to defective needle & needle too tight or loose in the slot.  Dirty needle slot.
  13. 13. Root Causes:  Cotton not stored in a clean and proper place.  Improper working method & environment. Fault Category Major Fault Code 320 CONTAMINATION
  14. 14. Root Causes:  Poor quality yarn & due to overheating of needle.  Yarn tension too tight. Fault Category Major Fault Code 300 KNIT HOLE
  15. 15. Root Causes:  The tension variation.  Hairiness is also the reason of this defect. Fault Category Major Fault Code 303 BIRD EYE
  16. 16. Fault Category Major Fault Code 340 SHADED COLLAR
  17. 17. Fault Category Major Fault Code 415 FRONT BACK SHADE
  18. 18. Fault Category Major Fault Code 617 SLEEVE SHADE VARIATION
  19. 19. Fault Category Major Fault Code 340 SIDE VENT TAPE SHADE
  20. 20. Root Causes In Dying Process:  Material having dead fibers or other defective fibers.  Material not properly desized.  Absorbency of the fabric not proper.  Impurities are not properly removed.  Uneven heat treatment during dying.  More hardness of water.  pH of water not proper.  Improper weight ratio of material, water, and chemicals.  Improper material to water ratio.  Defective instruments controlling temperature, pressure, speed etc. Other Causes:  It arises due to improper cutting, bundling and numbering.  When sequence of the fabric is not followed in sewing.  When parts / component are mixed in sewing.  Missing parts / components in bundling.  Due to dying problem & PTP shade in lot. SHADE VARIATION
  21. 21. Fault Category Major Fault Code 313 CALENDER / COMPACTOR MARK Root Causes:  Poor opening of fabric roll while feeding.  If pump pressure and reel speed in not equal.
  22. 22. Root Causes:  Printing paper quality is not good.  Low quality printing material. Fault Category Major Fault Code 125 TINT AT HTL
  23. 23. Root Causes:  Improper handling of buttons in manufacturing process.  Improper handling in sewing. Fault Category Major Fault Code 356 DAMAGE BUTTON HOLE
  24. 24. Root Causes:  Improper cut part handling by machine operator.  Low skill level of machine operator. Fault Category Major Fault Code 357 PLACKET BOX SLANT
  25. 25. Root Causes:  Improper reverse at edges of label.  Negligence of inspectors or clippers. Fault Category Major Fault Code 381 LABEL NOT SECURE
  26. 26. Root Causes:  Loppers threads are too tight. Fault Category Major Fault Code 800 PIPING
  27. 27. Root Causes:  Placket att. @mills might be improper & cutting uneven by scissor.  Cutting uneven at shoulder & sleeve attached. Fault Category Major Fault Code 397 PLACKET SLANT
  28. 28. Root Causes:  Low quality of label material & Improper label inspection method.  Improper time, temperature and pressure of machine. Fault Category Major Fault Code 400 DAMAGE / CRACKED LABEL
  29. 29. Root Causes:  Harshness of fabric.  Ensure correct type/size needles are used. Fault Category Major Fault Code 401 NEEDLE CUT
  30. 30. Root Causes:  Due to excessive pressure of presser foot.  Feed dog height is improper or too high. Fault Category Major Fault Code 405 FEED CUT
  31. 31. Root Causes:  Too much pressure of machine presser foot.  Too much machine heat not as per requirement. Fault Category Major Fault Code 437 SHINE MARK AT LABEL
  32. 32. Root Causes:  Improper cutting of shoulder by machine operators.  Attachment of collar without marking. Fault Category Major Fault Code 458 CROOKED COLLAR
  33. 33. Root Causes:  Incorrect threading & improper clamping of needle.  Compatibility of thread to fabric not correct. Fault Category Major Fault Code 503 SKIP / DROP STITCH
  34. 34. Fault Category Major Fault Code 317 OIL SPOT Root Causes:  Due to machine oil & due to handling.  Due to poor house keeping & improper oil level or external lubrication.
  35. 35. Root Causes:  This happens due to improper handling of the parts of garments.  Improper setting and timing between needles and looped or hooks etc. Fault Category Major Fault Code 520 OPEN SEAM
  36. 36. Root Causes:  Improper handling of cut parts by machine operator while feeding in machine.  Speedy work by machine operator & inaccuracy in cutting parts. Fault Category Major Fault Code 521 PLEAT
  37. 37. Root Causes:  When operator pulls the fabric not properly & fabric parts are not equal in length.  When upper & lower thread tension is tight but fabric is relaxed. Fault Category Major Fault Code 528 PUCKERING
  38. 38. Root Causes:  Improper handling and low skill level of operator.  Higher machine R.P.M (Round Per Minute). Fault Category Major Fault Code 532 RUN OFF SEAM
  39. 39. Root Causes:  Machine operator skill level is low.  Negligence of machine operator.  Trimming of thread at rework area is not proper before rework. Fault Category Major Fault Code 533 POOR REWORK
  40. 40. Root Causes:  Panel width variation from cutting department.  Negligence of machine operator.  Extra panel cutting by machine operator. Fault Category Major Fault Code 537 POUCH WIDTH VARIATION
  41. 41. Fault Category Major Fault Code 505 BROKEN STITCH Root Causes:  Poor quality thread & improper lubrication or waxing.  High pilling effect & incorrect T.P.I.
  42. 42. Root Causes:  Machine cutter is not properly working.  Auto trimmer machine not used for such operations. Fault Category Major Fault Code 542 RAW EDGE
  43. 43. Root Causes:  Working out of flow & extra handling & work load.  Machine operator’s negligence and not completing all operations. Fault Category Major Fault Code 563 OPERATION MISS
  44. 44. Root Causes:  Uneven panel cutting from cutting department.  Negligence of machine operator.  Extra panel cutting by machine operator. Fault Category Major Fault Code 567 INSEAM VARIATION
  45. 45. Root Causes:  Poor quality thread & thread tension too tight.  Improper lubrication or waxing & Wrong threading of machine. Fault Category Major Fault Code 582 BUTTON THREAD MISSING
  46. 46. Root Causes:  Improper tacking at collar attachment operation.  Due to wrong button placement. Fault Category Major Fault Code 586 PLACKET HIGH LOW
  47. 47. Root Causes:  Wrong button marking by machine operator.  Wrong placement of buttons while attachment. Fault Category Major Fault Code 591 BUTTON ALIGNMENT OUT
  48. 48. Root Causes:  Negligence & poor handling of machine operator & stitch bite is thin.  Higher machine R.P.M (Round Per Minute). Fault Category Major Fault Code 592 SEAM SLIP
  49. 49. Root Causes:  Improper handling of front and back parts by machine operator.  Wrong size front and back parts attachment & mixing of cut parts in bundles. Fault Category Major Fault Code 623 SIDE / OUTSEAM TWISTED
  50. 50. Root Causes:  Due to cutting problem from cutting department.  Due to high length wise shrinkage of fabric. Fault Category Major Fault Code 701 BODY LENGTH PLUS / MINUS
  51. 51. Root Causes:  Extra machine cutting while belt making.  Negligence of machine operator and size wise belt mixing in sewing. Fault Category Major Fault Code 702 WAIST PLUS / MINUS
  52. 52. Root Causes:  Mix size label in packet received from vendor.  Mix size label provided to machine operator. Fault Category Major Fault Code 717 WRONG SIZE LABEL
  53. 53. Root Causes:  Neck width plus and minus from cutting department.  Negligence & mishandling of press man while pressing the garment. Fault Category Major Fault Code 743 NECK WIDTH PLUS / MINUS
  54. 54. Root Causes:  Length variation of cuff from cutting.  Improper inspection methods. Fault Category Major Fault Code 750 SLEEVE OPENING VARIATION
  55. 55. Root Causes:  Length variation of cuff from cutting.  Improper inspection methods.  Uneven or extra cutting by machine operator while cuff making. Fault Category Major Fault Code 750 CUFF OPENING VARIATION
  56. 56. Root Causes:  Negligence & low skill level of machine operator.  Panel cutting uneven by machine operator. Fault Category Major Fault Code 759 ARMHOLE SHAPE OUT
  57. 57. Root Causes:  Wrong marking for pocket placement.  Machine operator handling problem while placing the pocket. Fault Category Major Fault Code 788 POCKET SLANT
  58. 58. Root Causes:  Cutting fault at mills & due to poor press.  Improper feeding of fabric. Fault Category Major Fault Code 801 BOTTOM SHAPE OUT
  59. 59. Root Causes:  Neck shape out or uneven neck cutting from cutting department.  Improper machine cutting by machine operator. Fault Category Major Fault Code 801 NECK SHAPE OUT
  60. 60. Fault Category Major Fault Code 806 DAMAGE NECK TAPE Root Causes:  Loose knitting of neck tape.  Damage feed dogs of machine.
  61. 61. Root Causes:  Negligence of machine operator & due to wrong size ID label.  Mix size care label received in a packet from vendor. Fault Category Major Fault Code 819 WRONG SIZE CARE LABEL
  62. 62. Root Causes:  Operator pasting w/o marking center of garment.  Operator's mishandling/carelessness. Fault Category Major Fault Code 820 LABEL CENTER OUT
  63. 63. Root Causes:  Label wrapper cutting is uneven.  Machine operator handling problem while pasting the label. Fault Category Major Fault Code 823 HTL SLANT
  64. 64. Root Causes:  Wrong size cutting of bottom rib from cutting department.  Mix size induction in the sewing lines & negligence of machine operators. Fault Category Major Fault Code 828 WRONG SIZE BOTTOM RIB
  65. 65. Root Causes:  Machine operator’s handling problem.  Uneven cutting of panel at bottom. Fault Category Major Fault Code 850 ROOPING
  66. 66. Root Causes:  Improper thread tension of loopers.  Thread tensionors are not working properly. Fault Category Major Fault Code 852 GRAINING
  67. 67. Root Causes:  Due to extra cutting at sleeve hem operation.  Sleeve length variation from cutting department. Fault Category Major Fault Code 853 WRONG SIZE SLEEVE
  68. 68. Root Causes:  Button not properly attached or placed at placket.  Placket template not placed properly. Fault Category Major Fault Code 861 EXPOSED PLACKET
  69. 69. FRAME MARK AT LOGO Fault Category Major Fault Code 863 Root Causes:  Too much pressure of machine presser foot.  Too much machine heat not as per requirement.  Machine bed surface is not properly even.  Machine bed surface is too hard.
  70. 70. Root Causes:  Extra fabric cutting at waistband & leg hem operation.  Uneven cutting of cut parts.  Extra shrinkage of garment after washing. Fault Category Major Fault Code 888 OUTSEAM PLUS / MINUS
  71. 71. Root Causes:  Uneven cutting of rib from cutting department.  Low skill level of machine operation. Fault Category Major Fault Code 937 NECK RIB HEIGHT UNEVEN
  72. 72. Fault Category Major Fault Code 992 DAMAGE DRAW CORD Root Causes:  Draw cord manufacturing machine problem.
  73. 73. Root Causes:  Wrong placement of button during attachment.  Damage button received from vendor. Fault Category Major Fault Code 995 DAMAGE BUTTON
  74. 74. Root Causes:  Induction in burst poly bags & Quality inspector’s hands are not clean.  Machines are not properly clean. Fault Category Major Fault Code 319 SOIL / DUST SPOT
  75. 75. Root Causes:  Negligence of machine operator. Fault Category Major Fault Code 508 REVERSE LABEL ATTACH
  76. 76. Root Causes:  Mishandling of pencil, chalk mark by staff. Fault Category Major Fault Code 857 PENCIL MARK
  77. 77. Root Causes:  Sharp edges of inspection tables, machine and cutters.  Negligence of inspectors, clippers, and machine operators. Fault Category Major Fault Code 824 DARNING
  78. 78. Root Causes:  Negligence of the quality inspectors & Wrong method of handling clippers.  Usage of sharp edge clippers instead of round edge clippers. Fault Category Major Fault Code 504 CUT HOLE
  79. 79. Root Causes:  Extra wastage of thread during sewing.  Negligence of clipper, machine operator and inspectors. Fault Category Major Fault Code 805 UNCUT / HANG THREAD
  80. 80. Root Causes:  Negligence of R&I supervisor, machine operator & quality staff.  No information available in PPC file regarding thread color. Fault Category Major Fault Code 940 WRONG COLOR THREAD
  81. 81. Fault Category Major Fault Code 759 MIS-SHAPED ARMHOLE Root Causes:  Negligence & low skill level of machine operator.  Panel cutting uneven by machine operator.
  82. 82. Root Causes:  Wrong marking for pocket placement.  Machine operator handling problem while placing the pocket. Fault Category Major Fault Code 788 POCKET SLANT
  83. 83. Fault Category Major Fault Code 801 BOTTOM SHAPE OUT Root Causes:  Cutting fault at mills & due to poor press.  Improper feeding of fabric.
  84. 84. Root Causes:  Wrong issuance of label from store, negligence of R&I supervisor, operator.  Mixing in label box. Fault Category Major Fault Code 819 WRONG SEASON LABEL
  85. 85. Root Causes:  Low quality pasting material.  Machine pressure, temperature and time is not as per requirement. Fault Category Major Fault Code 412 LABEL PEEL OFF
  86. 86. Root Causes:  Machine pressure is not as it should be.  Improper handling of parts. Fault Category Major Fault Code 466 EYE LET INSECURE
  87. 87. Root Causes:  Uneven cutting from cutting department.  Machine operator handling problem. Fault Category Major Fault Code 538 UNEVEN PANEL HEIGHT
  88. 88. Root Causes:  Uneven cutting from cutting department.  Machine operator handling problem. Fault Category Major Fault Code 538 PANEL WIDTH VARIATION
  89. 89. Root Causes:  Uneven cutting from cutting department.  Machine operator handling problem. Fault Category Major Fault Code 977 LEG SHAPE OUT
  90. 90. Root Causes:  Machine operator handling problem.  Stripes not locked while cutting in cutting department. Fault Category Major Fault Code 554 STRIPES MISMATCH
  91. 91. Root Causes:  Uneven cutting from cutting department.  Machine operator handling problem & extra parts cutting due to machine. Fault Category Major Fault Code 707 SHOULDER WIDTH VARIATION
  92. 92. Root Causes:  Printing material not properly mixed.  Material not properly cured. Fault Category Major Fault Code 617 PRINTING SHADE VARIATION
  93. 93. Root Causes:  Material not properly cured.  Quality of printing material is low. Fault Category Major Fault Code 929 DAMAGE / MISS PRINTING
  94. 94. Root Causes:  Improper handling of machine operator. Fault Category Major Fault Code 995 LOOP DAMAGE
  95. 95. Root Causes:  Improper handling of machine operator.  Label wrapper cutting is not proper from edges. Fault Category Major Fault Code 823 LOGO LABEL SLANT
  96. 96. Root Causes:  Machine operator is not following the sleeve notches.  Notches missing while cutting the fabric. Fault Category Major Fault Code 599 SLEEVE TWISTED
  97. 97. Root Causes:  Machine operator handling is not proper. Fault Category Major Fault Code 538 UNEVEN SEAM AT WAISTBAND
  98. 98. Root Causes:  Handling problem while making elastic ring. Fault Category Major Fault Code 552 DAMAGED ELASTIC
  99. 99. Root Causes:  Wrong placement of frame while embroidery of logo. Fault Category Major Fault Code 516 EMBRIDERY SEWN INTO SEAM
  100. 100. Root Causes:  Wrong placement of frame while printing. Fault Category Major Fault Code 516 PRINTING SEWN INTO SEAM
  101. 101. Fault Category Major Fault Code 824 DARNING Root Causes:  Sharp edges of inspection tables, machine and cutters.  Negligence of inspectors, clippers, and machine operators.
  102. 102. Root Causes:  Improper secure & operation miss. Fault Category Major Fault Code 995 DRAW CORD TIP MISS
  103. 103. Root Causes:  Low quality thread or machine problem. Fault Category Major Fault Code 995 DAMAGE EMBRIODERY
  104. 104. Root Causes:  Improper handling of machine operator while placing the pocket.  Improper marking for pockets. Fault Category Major Fault Code 764 POCKET HIGH LOW
  105. 105. Root Causes:  Wrong placement of label by machine operator while pasting it.  Improper machine cutting by machine operator. Fault Category Major Fault Code 606 MAIN LABEL PLACEMENT OUT
  106. 106. Root Causes:  Wrong issuance of thread from store, negligence of R&I supervisor, operator.  No information in PPC file and communication regarding thread. Fault Category Major Fault Code 891 WRONG COLOR THREAD
  107. 107. Root Causes:  Negligence of final inspector and packer.  Final inspector is not inspecting the garment from inside. Fault Category Major Fault Code 903 UNCUT ID LABEL
  108. 108. Root Causes :  Using eatable things in the unit  Negligence of the staff  No awareness Fault Category Critical Fault Code 459 DEAD BUGS
  109. 109. Root Causes :  Due to not following needle issue method  Due to not using metal detector machine properly.  Without replacement needle issued to operator. Fault Category Critical Fault Code 440 BROKEN NEEDLE
  110. 110. Root Causes:  SPI not as per requirement or standards.  Machine is not properly working. Fault Category Critical (Child) Fault Code 465 INSECURE BUTTON
  111. 111. Root Causes:  Improper cleanliness of work places.  Workers are touching their hands with their hairs during work. Fault Category Critical Fault Code 176 LOOSE HAIR
  112. 112. Root Causes:  Sharp edges at work place.  Insects at your work place. Fault Category Critical Fault Code 452 BLOOD STAIN
  113. 113. Root Causes:  Negligence of machine operator & mix label provided to machine operator.  No information about label or fabric content provided. Fault Category Critical Fault Code 632 WRONG CONTENT LABEL
  114. 114. 495 Stones Left in Pocket after Wash (Children) Critical 471 Closures with Sharp Edges (Children) Critical 463 Damaged/Broken Closures (Children) Critical 467 Drawstring/Cord not Tacked (Children) Critical 473 Improper Placement of Drawstring (Children) Critical 465 Insecure Button (Children) Critical 474 Unwanted Sharp Point / Sharp Edge Critical 477 Improper length of Drawstring (Children) Critical 488 Minimum Neck Stretch Minus (Children) Critical 468 Hand Sewn Buttons/Trims (Children) Critical 487 Sharp Tool Critical 478 Sharp point /Sharp edge/Staples/Pins Critical 409 Improper Country of Origin Label Critical 445 Missing / Incorrect Tracking Label (Children) Critical 454 Missing Care Instruction Label Critical 447 Missing Country of Origin Label Critical 994 Wrong Fiber Content Critical
  115. 115. Root Causes:  Negligence of packer. Fault Category Major Fault Code 218 OCR STICKER MISS
  116. 116. Root Causes:  Negligence of packer. Fault Category Major Fault Code 652 WRONG SIZE GARMENT IN PACK
  117. 117. Root Causes:  Negligence of packer. Fault Category Major Fault Code 686 WRONG ASSORTMENT
  118. 118. Root Causes:  Negligence of packer. Fault Category Major Fault Code 217 WRONG SIZE UPC STICKER

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