Prepared By: Abdul Latif Asst. Manager.QA MTM-Faisalabad Pakistan +923127274200

1. Prepared By: Abdul Latif (AM.QA)
2016-2017
Training & Development Wing
Quality Assurance

2. 2

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. 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 312
THICK & THIN YARN

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

6. Root Causes:
 Due to defective needle & needle too tight or loose in the slot.
 Dirty needle slot.
KNITTING LINE
Fault Category Major Fault Code 354

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

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

9. SHADED COLLAR
Fault Category Major Fault Code 340

10. FRONT BACK SHADE
Fault Category Major Fault Code 415

11. SLEEVE SHADE VARIATION
Fault Category Major Fault Code 617

12. 12
SHADED COLLAR
Fault Category Major Fault Code 340
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.

13. CALENDER / COMPACTOR MARK
Fault Category Major Fault Code 313
Root Causes:
 Poor opening of fabric roll while feeding.
 If pump pressure and reel speed in not equal.

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

15. OIL SPOT
Fault Category Major Fault Code 317
Root Causes:
 Due to machine oil & due to handling.
 Due to poor house keeping & improper oil level or external lubrication.

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

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

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

19. 19
PLACKET SLANT
Fault Category Major Fault Code 397
Root Causes:
 Placket att. @mills might be improper & cutting uneven by scissor.
 Cutting uneven at shoulder & sleeve attached.

20. DAMAGE LABEL
Fault Category Major Fault Code 399
Root Causes:
 Low quality of label material & Improper label inspection method.
 Improper time, temperature and pressure of machine.

21. DAMAGE / CRACKED LABEL
Fault Category Major Fault Code 400
Root Causes:
 Low quality of label material & Improper label inspection method.
 Improper time, temperature and pressure of machine.

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

23. FEED CUT
Fault Category Major Fault Code 405
Root Causes:
 Due to excessive pressure of presser foot.
 Feed dog height is improper or too high.

24. SHINE MARK AT LABEL
Fault Category Major Fault Code 437
Root Causes:
 Too much pressure of machine presser foot.
 Too much machine heat not as per requirement.

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

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

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

28. OPEN SEAM
Fault Category Major Fault Code 520
Root Causes:
 This happens due to improper handling of the parts of garments.
 Improper setting and timing between needles and looped or hooks etc.

29. PLEAT
Fault Category Major Fault Code 521
Root Causes:
 Improper handling of cut parts by machine operator while feeding in machine.
 Speedy work by machine operator & inaccuracy in cutting parts.

30. PUCKERING
Fault Category Major Fault Code 528
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.

31. RUN OFF SEAM
Fault Category Major Fault Code 532
Root Causes:
 Improper handling and low skill level of operator.
 Higher machine R.P.M (Round Per Minute).

32. POOR REWORK
65
Fault Category Major Fault Code 533
Root Causes:
 Machine operator skill level is low.
 Negligence of machine operator.
 Trimming of thread at rework area is not proper before rework.

33. POUCH WIDTH VARIATION
67
Fault Category Major Fault Code 537
Root Causes:
 Panel width variation from cutting department.
 Negligence of machine operator.
 Extra panel cutting by machine operator.

34. UNEVEN SIDE SEAM
69
Fault Category Major Fault Code 538
Root Causes:
 Side uneven cutting from cutting department.
 Negligence of machine operator.
 Extra panel cutting by machine operator.

35. 71
RAW EDGE
Fault Category Major Fault Code 542
Root Causes:
 Machine cutter is not properly working.
 Auto trimmer machine not used for such operations.

36. 73
OPERATION MISS
Fault Category Major Fault Code 563
Root Causes:
 Working out of flow & extra handling & work load.
 Machine operator’s negligence and not completing all operations.

37. 75
INSEAM VARIATION
Fault Category Major Fault Code 567
Root Causes:
 Uneven panel cutting from cutting department.
 Negligence of machine operator.
 Extra panel cutting by machine operator.

38. BUTTON THREAD MISSING
77
Fault Category Major Fault Code 582
Root Causes:
 Poor quality thread & thread tension too tight.
 Improper lubrication or waxing & Wrong threading of machine.

39. 79
PLACKET HIGH LOW
Fault Category Major Fault Code 586
Root Causes:
 Improper tacking at collar attachment operation.
 Due to wrong button placement.

40. 81
BUTTON ALIGNMENT OUT
Fault Category Major Fault Code 591
Root Causes:
 Wrong button marking by machine operator.
 Wrong placement of buttons while attachment.

41. SEAM SLIP
83
Fault Category Major Fault Code 592
Root Causes:
 Negligence & poor handling of machine operator & stitch bite is thin.
 Higher machine R.P.M (Round Per Minute).

42. TWISTED SLEEVE
85
Fault Category Major Fault Code 599
Root Causes:
 Machine operator is not following the sleeve notches.
 Notches missing while cutting the fabric.

43. SIDE / OUTSEAM TWISTED
Fault Category Major Fault Code 623
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.

44. BODY LENGTH PLUS / MINUS
95
Fault Category Major Fault Code 701
Root Causes:
 Due to cutting problem from cutting department.
 Due to high length wise shrinkage of fabric.

45. 97
WAIST PLUS / MINUS
Fault Category Major Fault Code 702
Root Causes:
 Extra machine cutting while belt making.
 Negligence of machine operator and size wise belt mixing in sewing.

46. WRONG SIZE LABEL
99
Fault Category Major Fault Code 717
Root Causes:
 Mix size label in packet received from vendor.
 Mix size label provided to machine operator.

47. NECK WIDTH PLUS / MINUS
101
Fault Category Major Fault Code 743
Root Causes:
 Neck width plus and minus from cutting department.
 Negligence & mishandling of press man while pressing the garment.

48. SLEEVE OPENING VARIATION
103
Fault Category Major Fault Code 750
Root Causes:
 Length variation of cuff from cutting.
 Improper inspection methods.

49. 105
CUFF OPENING VARIATION
Fault Category Major Fault Code 750
Root Causes:
 Length variation of cuff from cutting.
 Improper inspection methods.
 Uneven or extra cutting by machine operator while cuff
making.

50. 107
MIS-SHAPED ARMHOLE
Fault Category Major Fault Code 759
Root Causes:
 Negligence & low skill level of machine operator.
 Panel cutting uneven by machine operator.

51. POCKET SLANT
109
Fault Category Major Fault Code 788
Root Causes:
 Wrong marking for pocket placement.
 Machine operator handling problem while placing the pocket.

52. BOTTOM SHAPE OUT
111
Fault Category Major Fault Code 801
Root Causes:
 Cutting fault at mills & due to poor press.
 Improper feeding of fabric

53. NECK SHAPE OUT
113
Fault Category Major Fault Code 801
Root Causes:
 Neck shape out or uneven neck cutting from cutting department.
 Improper machine cutting by machine operator.

54. DAMAGE NECK TAPE
119
Fault Category Major Fault Code 806
Root Causes:
 Loose knitting of neck tape.
 Damage feed dogs of machine.

55. WRONG SIZE CARE LABEL
121
Fault Category Major Fault Code 819
Root Causes:
 Negligence of machine operator & due to wrong size ID label.
 Mix size care label received in a packet from vendor.

56. LABEL CENTER OUT
123
Fault Category Major Fault Code 820
Root Causes:
 Operator pasting w/o marking center of garment.
 Operator's mishandling/carelessness.

57. 125
HEAT TRANSFER LABEL SLANT
Fault Category Major Fault Code 823
Root Causes:
 Label wrapper cutting is uneven.
 Machine operator handling problem while pasting the label.

58. 129
WRONG SIZE BOTTOM RIB
Fault Category Major Fault Code 828
Root Causes:
 Wrong size cutting of bottom rib from cutting department.
 Mix size induction in the sewing lines & negligence of machine operators.

59. ROOPING
131
Fault Category Major Fault Code 850
Root Causes:
 Machine operator’s handling problem.
 Uneven cutting of panel at bottom.

60. 135
WRONG SIZE SLEEVE
Fault Category Major Fault Code 853
Root Causes:
 Due to extra cutting at sleeve hem operation.
 Sleeve length variation from cutting department.

61. EXPOSED PLACKET
139
Fault Category Major Fault Code 861
Root Causes:
 Button not properly attached or placed at placket.
 Placket template not placed properly.

62. FRAME MARK AT LOGO
141
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.

63. OUT SEAM PLUS / MINUS
Fault Category Major Fault Code 888
143
Root Causes:
 Extra fabric cutting at waistband & leg hem operation.
 Uneven cutting of cut parts.
 Extra shrinkage of garment after washing.

64. NECK RIB HEIGHT UNEVEN
147
Fault Category Major Fault Code 937
Root Causes:
 Uneven cutting of rib from cutting department.
 Low skill level of machine operation.

65. 149
DAMAGE DRAW CORD
Fault Category Major Fault Code 992
Root Causes:
 Draw cord manufacturing machine problem.

66. 153
DAMAGE BUTTON
Fault Category Major Fault Code 995
Root Causes:
 Wrong placement of button during attachment.
 Damage button received from vendor.

67. SOIL / DUST SPOT
17
Fault Category Major Fault Code 319
Root Causes:
 Induction in burst poly bags & Quality inspector’s hands are not clean.
 Machines are not properly clean.

68. CUT HOLE
55
Fault Category Major Fault Code 504
Root Causes:
 Negligence of the quality inspectors & Wrong method of handling clippers.
 Usage of sharp edge clippers instead of round edge clippers.

69. 117
UNCUT / HANG THREAD
Fault Category Major Fault Code 805
Root Causes:
 Extra wastage of thread during sewing.
 Negligence of clipper, machine operator and inspectors.

70. DARNING
127
Fault Category Major Fault Code 824
Root Causes:
 Sharp edges of inspection tables, machine and cutters.
 Negligence of inspectors, clippers, and machine operators.

71. PENCIL MARK
137
Fault Category Major Fault Code 857
Root Causes:
 Mishandling of pencil, chalk mark by staff.

72. 72
Fault Category Major Fault Code 617
PRINTING SHADE VARIATION
89
Root Causes:
 Printing material not properly mixed.
 Material not properly cured.

73. 145
DAMAGE / MISS PRINTING
Fault Category Major Fault Code 929
Root Causes:
 Material not properly cured.
 Quality of printing material is low.

74. 74

75. 75
Dead Bugs
Fault Category Critical Fault Code 459
Root Causes :
 Using eatable things in the unit
 Negligence of the staff.
 No awareness

76. 76
Root Causes :
 Due to not following needle issue method
 Due to not using metal detector machine properly.
 Without replacement needle issued to operator.
BROKEN NEEDLE
Fault Category Critical Fault Code 440

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

78. 93
WRONG CONTENT LABEL
Fault Category Critical Fault Code 632
Root Causes:
 Negligence of machine operator & mix label provided to machine operator.
 No information about label or fabric content provided.

79. 5
LOOSE HAIR
Fault Category Critical Fault Code 176
Root Causes:
 Improper cleanliness of work places.
 Workers are touching their hands with their hairs during work.

80. 80
Fault Category Critical Fault Code 452
BLOOD STAIN
47
Root Causes:
 Sharp edges at work place.
 Insects at your work place.

81. 81
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

82. 82