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.

1. Prepared By: Abdul Latif (AM.QA)
Cell # +92 312-7274200
Faisalabad
Pakistan
22-09-2016
2016-2017
Quality Assurance
Training & Development Wing

3. Root Causes:
 Due to dead fibers.
 Fibers length is very short.
 Re-dying process of fabric.
DEAD COTTON
Fault Category Major Fault Code 175

4. Root Causes:
 Re-dying process of fabric.
Fault Category Major Fault Code 391
PILLING

5. 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

6. Root Causes:
 Low quality yarn.
 Variations in count.
Fault Category Major Fault Code 312
THICK & THIN YARN

7. 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

8. Root Causes:
 Breakage of yarn during knitting process.
Fault Category Major Fault Code 361
MISSING YARN

9. Root Causes:
 Lack of adequate fiber control in the drafting zone.
Fault Category Major Fault Code 308
SLUB

10. Root Causes:
 Knitting machine problem & breakage of yarn during knitting process.
Fault Category Major Fault Code 331
PRESS OFF

11. Root Causes:
 Due to rusty equipment.
Fault Category Major Fault Code 315
RUST MAKR

12. Root Causes:
 Breakage of lycra yarn during knitting process.
Fault Category Major Fault Code 392
LYCRA SHORT

13. 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.

14. Root Causes:
 Cotton not stored in a clean and proper place.
 Improper working method & environment.
Fault Category Major Fault Code 320
CONTAMINATION

15. Root Causes:
 Poor quality yarn & due to overheating of needle.
 Yarn tension too tight.
Fault Category Major Fault Code 300
KNIT HOLE

16. Root Causes:
 The tension variation.
 Hairiness is also the reason of this defect.
Fault Category Major Fault Code 303
BIRD EYE

18. Fault Category Major Fault Code 340
SHADED COLLAR

19. Fault Category Major Fault Code 415
FRONT BACK SHADE

20. Fault Category Major Fault Code 617
SLEEVE SHADE VARIATION

21. Fault Category Major Fault Code 340
SIDE VENT TAPE SHADE

22. 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

23. 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.

25. Root Causes:
 Printing paper quality is not good.
 Low quality printing material.
Fault Category Major Fault Code 125
TINT AT HTL

26. Root Causes:
 Improper handling of buttons in manufacturing process.
 Improper handling in sewing.
Fault Category Major Fault Code 356
DAMAGE BUTTON HOLE

27. Root Causes:
 Improper cut part handling by machine operator.
 Low skill level of machine operator.
Fault Category Major Fault Code 357
PLACKET BOX SLANT

28. Root Causes:
 Improper reverse at edges of label.
 Negligence of inspectors or clippers.
Fault Category Major Fault Code 381
LABEL NOT SECURE

29. Root Causes:
 Loppers threads are too tight.
Fault Category Major Fault Code 800
PIPING

30. 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

31. 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

32. Root Causes:
 Harshness of fabric.
 Ensure correct type/size needles are used.
Fault Category Major Fault Code 401
NEEDLE CUT

33. 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

34. 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

35. Root Causes:
 Improper cutting of shoulder by machine operators.
 Attachment of collar without marking.
Fault Category Major Fault Code 458
CROOKED COLLAR

36. Root Causes:
 Incorrect threading & improper clamping of needle.
 Compatibility of thread to fabric not correct.
Fault Category Major Fault Code 503
SKIP / DROP STITCH

37. 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.

38. 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

39. 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

40. 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

41. 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

42. 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

43. 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

44. Fault Category Major Fault Code 505
BROKEN STITCH
Root Causes:
 Poor quality thread & improper lubrication or waxing.
 High pilling effect & incorrect T.P.I.

45. Root Causes:
 Machine cutter is not properly working.
 Auto trimmer machine not used for such operations.
Fault Category Major Fault Code 542
RAW EDGE

46. 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

47. 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

48. 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

49. Root Causes:
 Improper tacking at collar attachment operation.
 Due to wrong button placement.
Fault Category Major Fault Code 586
PLACKET HIGH LOW

50. Root Causes:
 Wrong button marking by machine operator.
 Wrong placement of buttons while attachment.
Fault Category Major Fault Code 591
BUTTON ALIGNMENT OUT

51. 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

52. 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

53. 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

54. 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

55. 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

56. 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

57. Root Causes:
 Length variation of cuff from cutting.
 Improper inspection methods.
Fault Category Major Fault Code 750
SLEEVE OPENING VARIATION

58. 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

59. Root Causes:
 Negligence & low skill level of machine operator.
 Panel cutting uneven by machine operator.
Fault Category Major Fault Code 759
ARMHOLE SHAPE OUT

60. Root Causes:
 Wrong marking for pocket placement.
 Machine operator handling problem while placing the pocket.
Fault Category Major Fault Code 788
POCKET SLANT

61. Root Causes:
 Cutting fault at mills & due to poor press.
 Improper feeding of fabric.
Fault Category Major Fault Code 801
BOTTOM SHAPE OUT

62. 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

63. Fault Category Major Fault Code 806
DAMAGE NECK TAPE
Root Causes:
 Loose knitting of neck tape.
 Damage feed dogs of machine.

64. 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

65. Root Causes:
 Operator pasting w/o marking center of garment.
 Operator's mishandling/carelessness.
Fault Category Major Fault Code 820
LABEL CENTER OUT

66. Root Causes:
 Label wrapper cutting is uneven.
 Machine operator handling problem while pasting the label.
Fault Category Major Fault Code 823
HTL SLANT

67. 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

68. Root Causes:
 Machine operator’s handling problem.
 Uneven cutting of panel at bottom.
Fault Category Major Fault Code 850
ROOPING

69. Root Causes:
 Improper thread tension of loopers.
 Thread tensionors are not working properly.
Fault Category Major Fault Code 852
GRAINING

70. 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

71. Root Causes:
 Button not properly attached or placed at placket.
 Placket template not placed properly.
Fault Category Major Fault Code 861
EXPOSED PLACKET

72. 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.

73. 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

74. 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

75. Fault Category Major Fault Code 992
DAMAGE DRAW CORD
Root Causes:
 Draw cord manufacturing machine problem.

76. Root Causes:
 Wrong placement of button during attachment.
 Damage button received from vendor.
Fault Category Major Fault Code 995
DAMAGE BUTTON

77. 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

78. Root Causes:
 Negligence of machine operator.
Fault Category Major Fault Code 508
REVERSE LABEL ATTACH

79. Root Causes:
 Mishandling of pencil, chalk mark by staff.
Fault Category Major Fault Code 857
PENCIL MARK

80. Root Causes:
 Sharp edges of inspection tables, machine and cutters.
 Negligence of inspectors, clippers, and machine operators.
Fault Category Major Fault Code 824
DARNING

81. 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

82. Root Causes:
 Extra wastage of thread during sewing.
 Negligence of clipper, machine operator and inspectors.
Fault Category Major Fault Code 805
UNCUT / HANG THREAD

83. 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

84. Fault Category Major Fault Code 759
MIS-SHAPED ARMHOLE
Root Causes:
 Negligence & low skill level of machine operator.
 Panel cutting uneven by machine operator.

85. Root Causes:
 Wrong marking for pocket placement.
 Machine operator handling problem while placing the pocket.
Fault Category Major Fault Code 788
POCKET SLANT

86. Fault Category Major Fault Code 801
BOTTOM SHAPE OUT
Root Causes:
 Cutting fault at mills & due to poor press.
 Improper feeding of fabric.

87. 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

88. 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

89. Root Causes:
 Machine pressure is not as it should be.
 Improper handling of parts.
Fault Category Major Fault Code 466
EYE LET INSECURE

90. Root Causes:
 Uneven cutting from cutting department.
 Machine operator handling problem.
Fault Category Major Fault Code 538
UNEVEN PANEL HEIGHT

91. Root Causes:
 Uneven cutting from cutting department.
 Machine operator handling problem.
Fault Category Major Fault Code 538
PANEL WIDTH VARIATION

92. Root Causes:
 Uneven cutting from cutting department.
 Machine operator handling problem.
Fault Category Major Fault Code 977
LEG SHAPE OUT

93. Root Causes:
 Machine operator handling problem.
 Stripes not locked while cutting in cutting department.
Fault Category Major Fault Code 554
STRIPES MISMATCH

94. 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

95. Root Causes:
 Printing material not properly mixed.
 Material not properly cured.
Fault Category Major Fault Code 617
PRINTING SHADE VARIATION

96. Root Causes:
 Material not properly cured.
 Quality of printing material is low.
Fault Category Major Fault Code 929
DAMAGE / MISS PRINTING

97. Root Causes:
 Improper handling of machine operator.
Fault Category Major Fault Code 995
LOOP DAMAGE

98. Root Causes:
 Improper handling of machine operator.
 Label wrapper cutting is not proper from edges.
Fault Category Major Fault Code 823
LOGO LABEL SLANT

99. Root Causes:
 Machine operator is not following the sleeve notches.
 Notches missing while cutting the fabric.
Fault Category Major Fault Code 599
SLEEVE TWISTED

100. Root Causes:
 Machine operator handling is not proper.
Fault Category Major Fault Code 538
UNEVEN SEAM AT WAISTBAND

101. Root Causes:
 Handling problem while making elastic ring.
Fault Category Major Fault Code 552
DAMAGED ELASTIC

102. Root Causes:
 Wrong placement of frame while embroidery of logo.
Fault Category Major Fault Code 516
EMBRIDERY SEWN INTO SEAM

103. Root Causes:
 Wrong placement of frame while printing.
Fault Category Major Fault Code 516
PRINTING SEWN INTO SEAM

104. Fault Category Major Fault Code 824
DARNING
Root Causes:
 Sharp edges of inspection tables, machine and cutters.
 Negligence of inspectors, clippers, and machine operators.

105. Root Causes:
 Improper secure & operation miss.
Fault Category Major Fault Code 995
DRAW CORD TIP MISS

106. Root Causes:
 Low quality thread or machine problem.
Fault Category Major Fault Code 995
DAMAGE EMBRIODERY

107. Root Causes:
 Improper handling of machine operator while placing the pocket.
 Improper marking for pockets.
Fault Category Major Fault Code 764
POCKET HIGH LOW

108. 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

109. 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

110. 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

112. Root Causes :
 Using eatable things in the unit
 Negligence of the staff
 No awareness
Fault Category Critical Fault Code 459
DEAD BUGS

113. 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

114. Root Causes:
 SPI not as per requirement or standards.
 Machine is not properly working.
Fault Category Critical (Child) Fault Code 465
INSECURE BUTTON

115. 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

116. Root Causes:
 Sharp edges at work place.
 Insects at your work place.
Fault Category Critical Fault Code 452
BLOOD STAIN

117. 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

118. 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

120. Root Causes:
 Negligence of packer.
Fault Category Major Fault Code 218
OCR STICKER MISS

121. Root Causes:
 Negligence of packer.
Fault Category Major Fault Code 652
WRONG SIZE GARMENT IN PACK

122. Root Causes:
 Negligence of packer.
Fault Category Major Fault Code 686
WRONG ASSORTMENT

123. Root Causes:
 Negligence of packer.
Fault Category Major Fault Code 217
WRONG SIZE UPC STICKER