fault library 2016-2017 by abdul latif (+92 3127274200)

Prepared By: Abdul Latif (AM.QA)Cell # +92 312-7274200

FaisalabadPakistan

22-09-2016

2016-2017

Fault Library

Quality AssuranceTraining & Development Wing

Masood Textile Mills (Apparel Division)

Major FaultsYarn-Fabric

Root Causes: Due to dead fibers. Fibers length is very short. Re-dying process of fabric.

DEAD COTTONFault Category Major Fault Code 175

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 frame drafting roller. Low pressure on drafting rollers.

YARN VARIATION

Root Causes: Low quality yarn. Variations in count.

THICK & THIN YARN

Root Causes: Manual picking of cotton seeds, stones, hairs, plastic material etc. Spinning area is not neat and clean.

CONTAMINATED YARN

Root Causes: Breakage of yarn during knitting process.

MISSING YARN

Root Causes: Lack of adequate fiber control in the drafting zone.

Root Causes: Knitting machine problem & breakage of yarn during knitting process.

PRESS OFF

Root Causes: Due to rusty equipment.

RUST MAKR

Root Causes: Breakage of lycra yarn during knitting process.

LYCRA SHORT

KNITTING LINE

Root Causes: Due to defective needle & needle too tight or loose in the slot. Dirty needle slot.

Root Causes: Cotton not stored in a clean and proper place. Improper working method & environment.

CONTAMINATION

Root Causes: Poor quality yarn & due to overheating of needle. Yarn tension too tight.

KNIT HOLE

Root Causes: The tension variation. Hairiness is also the reason of this defect.

BIRD EYE

Major FaultsDyeing-Processing-Finishing

SHADED COLLAR

FRONT BACK SHADE

SLEEVE SHADE VARIATION

SIDE VENT TAPE SHADE

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

CALENDER / COMPACTOR MARK

Root Causes: Poor opening of fabric roll while feeding. If pump pressure and reel speed in not equal.

Major FaultsCutting-Sewing-Finishing

Root Causes: Printing paper quality is not good. Low quality printing material.

TINT AT HTL

Root Causes: Improper handling of buttons in manufacturing process. Improper handling in sewing.

DAMAGE BUTTON HOLE

Root Causes: Improper cut part handling by machine operator. Low skill level of machine operator.

PLACKET BOX SLANT

Root Causes: Improper reverse at edges of label. Negligence of inspectors or clippers.

LABEL NOT SECURE

Root Causes: Loppers threads are too tight.

PIPING

Root Causes: Placket att. @mills might be improper & cutting uneven by scissor. Cutting uneven at shoulder & sleeve attached.

PLACKET SLANT

Root Causes: Low quality of label material & Improper label inspection method. Improper time, temperature and pressure of machine.

DAMAGE / CRACKED LABEL

Root Causes: Harshness of fabric. Ensure correct type/size needles are used.

NEEDLE CUT

Root Causes: Due to excessive pressure of presser foot. Feed dog height is improper or too high.

FEED CUT

Root Causes: Too much pressure of machine presser foot. Too much machine heat not as per requirement.

SHINE MARK AT LABEL

Root Causes: Improper cutting of shoulder by machine operators. Attachment of collar without marking.

CROOKED COLLAR

Root Causes: Incorrect threading & improper clamping of needle. Compatibility of thread to fabric not correct.

SKIP / DROP STITCH

OIL SPOT

Root Causes: Due to machine oil & due to handling. Due to poor house keeping & improper oil level or external lubrication.

Root Causes: This happens due to improper handling of the parts of garments. Improper setting and timing between needles and looped or hooks etc.

OPEN SEAM

Root Causes: Improper handling of cut parts by machine operator while feeding in machine. Speedy work by machine operator & inaccuracy in cutting parts.

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.

PUCKERING

Root Causes: Improper handling and low skill level of operator. Higher machine R.P.M (Round Per Minute).

RUN OFF SEAM

Root Causes: Machine operator skill level is low. Negligence of machine operator. Trimming of thread at rework area is not proper before rework.

POOR REWORK

Root Causes: Panel width variation from cutting department. Negligence of machine operator. Extra panel cutting by machine operator.

POUCH WIDTH VARIATION

BROKEN STITCH

Root Causes: Poor quality thread & improper lubrication or waxing. High pilling effect & incorrect T.P.I.

Root Causes: Machine cutter is not properly working. Auto trimmer machine not used for such operations.

RAW EDGE

Root Causes: Working out of flow & extra handling & work load. Machine operator’s negligence and not completing all operations.

OPERATION MISS

Root Causes: Uneven panel cutting from cutting department. Negligence of machine operator. Extra panel cutting by machine operator.

INSEAM VARIATION

Root Causes: Poor quality thread & thread tension too tight. Improper lubrication or waxing & Wrong threading of machine.

BUTTON THREAD MISSING

Root Causes: Improper tacking at collar attachment operation. Due to wrong button placement.

PLACKET HIGH LOW

Root Causes: Wrong button marking by machine operator. Wrong placement of buttons while attachment.

BUTTON ALIGNMENT OUT

Root Causes: Negligence & poor handling of machine operator & stitch bite is thin. Higher machine R.P.M (Round Per Minute).

SEAM SLIP

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.

SIDE / OUTSEAM TWISTED

Root Causes: Due to cutting problem from cutting department. Due to high length wise shrinkage of fabric.

BODY LENGTH PLUS / MINUS

Root Causes: Extra machine cutting while belt making. Negligence of machine operator and size wise belt mixing in sewing.

WAIST PLUS / MINUS

Root Causes: Mix size label in packet received from vendor. Mix size label provided to machine operator.

WRONG SIZE LABEL

Root Causes: Neck width plus and minus from cutting department. Negligence & mishandling of press man while pressing the garment.

NECK WIDTH PLUS / MINUS

Root Causes: Length variation of cuff from cutting. Improper inspection methods.

SLEEVE OPENING VARIATION

Root Causes: Length variation of cuff from cutting. Improper inspection methods. Uneven or extra cutting by machine operator while cuff making.

CUFF OPENING VARIATION

Root Causes: Negligence & low skill level of machine operator. Panel cutting uneven by machine operator.

ARMHOLE SHAPE OUT

Root Causes: Wrong marking for pocket placement. Machine operator handling problem while placing the pocket.

POCKET SLANT

Root Causes: Cutting fault at mills & due to poor press. Improper feeding of fabric.

BOTTOM SHAPE OUT

Root Causes: Neck shape out or uneven neck cutting from cutting department. Improper machine cutting by machine operator.

NECK SHAPE OUT

DAMAGE NECK TAPE

Root Causes: Loose knitting of neck tape. Damage feed dogs of machine.

Root Causes: Negligence of machine operator & due to wrong size ID label. Mix size care label received in a packet from vendor.

WRONG SIZE CARE LABEL

Root Causes: Operator pasting w/o marking center of garment. Operator's mishandling/carelessness.

LABEL CENTER OUT

Root Causes: Label wrapper cutting is uneven. Machine operator handling problem while pasting the label.

HTL SLANT

Root Causes: Wrong size cutting of bottom rib from cutting department. Mix size induction in the sewing lines & negligence of machine operators.

WRONG SIZE BOTTOM RIB

Root Causes: Machine operator’s handling problem. Uneven cutting of panel at bottom.

ROOPING

Root Causes: Improper thread tension of loopers. Thread tensionors are not working properly.

GRAINING

Root Causes: Due to extra cutting at sleeve hem operation. Sleeve length variation from cutting department.

WRONG SIZE SLEEVE

Root Causes: Button not properly attached or placed at placket. Placket template not placed properly.

EXPOSED PLACKET

FRAME MARK AT LOGOFault 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.

Root Causes: Extra fabric cutting at waistband & leg hem operation. Uneven cutting of cut parts. Extra shrinkage of garment after washing.

OUTSEAM PLUS / MINUS

Root Causes: Uneven cutting of rib from cutting department. Low skill level of machine operation.

NECK RIB HEIGHT UNEVEN

DAMAGE DRAW CORD

Root Causes: Draw cord manufacturing machine problem.

Root Causes: Wrong placement of button during attachment. Damage button received from vendor.

DAMAGE BUTTON

Root Causes: Induction in burst poly bags & Quality inspector’s hands are not clean. Machines are not properly clean.

SOIL / DUST SPOT

Root Causes: Negligence of machine operator.

REVERSE LABEL ATTACH

Root Causes: Mishandling of pencil, chalk mark by staff.

PENCIL MARK

Root Causes: Sharp edges of inspection tables, machine and cutters. Negligence of inspectors, clippers, and machine operators.

DARNING

Root Causes: Negligence of the quality inspectors & Wrong method of handling clippers. Usage of sharp edge clippers instead of round edge clippers.

CUT HOLE

Root Causes: Extra wastage of thread during sewing. Negligence of clipper, machine operator and inspectors.

UNCUT / HANG THREAD

Root Causes: Negligence of R&I supervisor, machine operator & quality staff. No information available in PPC file regarding thread color.

WRONG COLOR THREAD

MIS-SHAPED ARMHOLE

Root Causes: Negligence & low skill level of machine operator. Panel cutting uneven by machine operator.

Root Causes: Wrong marking for pocket placement. Machine operator handling problem while placing the pocket.

POCKET SLANT

BOTTOM SHAPE OUT

Root Causes: Cutting fault at mills & due to poor press. Improper feeding of fabric.

Root Causes: Wrong issuance of label from store, negligence of R&I supervisor, operator. Mixing in label box.

WRONG SEASON LABEL

Root Causes: Low quality pasting material. Machine pressure, temperature and time is not as per requirement.

LABEL PEEL OFF

Root Causes: Machine pressure is not as it should be. Improper handling of parts.

EYE LET INSECURE

Root Causes: Uneven cutting from cutting department. Machine operator handling problem.

UNEVEN PANEL HEIGHT

PANEL WIDTH VARIATION

LEG SHAPE OUT

Root Causes: Machine operator handling problem. Stripes not locked while cutting in cutting department.

STRIPES MISMATCH

Root Causes: Uneven cutting from cutting department. Machine operator handling problem & extra parts cutting due to machine.

SHOULDER WIDTH VARIATION

Root Causes: Printing material not properly mixed. Material not properly cured.

PRINTING SHADE VARIATION

Root Causes: Material not properly cured. Quality of printing material is low.

DAMAGE / MISS PRINTING

Root Causes: Improper handling of machine operator.

LOOP DAMAGE

Root Causes: Improper handling of machine operator. Label wrapper cutting is not proper from edges.

LOGO LABEL SLANT

Root Causes: Machine operator is not following the sleeve notches. Notches missing while cutting the fabric.

SLEEVE TWISTED

Root Causes: Machine operator handling is not proper.

UNEVEN SEAM AT WAISTBAND

Root Causes: Handling problem while making elastic ring.

DAMAGED ELASTIC

Root Causes: Wrong placement of frame while embroidery of logo.

EMBRIDERY SEWN INTO SEAM

Root Causes: Wrong placement of frame while printing.

PRINTING SEWN INTO SEAM

DARNING

Root Causes: Sharp edges of inspection tables, machine and cutters. Negligence of inspectors, clippers, and machine operators.

Root Causes: Improper secure & operation miss.

DRAW CORD TIP MISS

Root Causes: Low quality thread or machine problem.

DAMAGE EMBRIODERY

Root Causes: Improper handling of machine operator while placing the pocket. Improper marking for pockets.

POCKET HIGH LOW

Root Causes: Wrong placement of label by machine operator while pasting it. Improper machine cutting by machine operator.

MAIN LABEL PLACEMENT OUT

Root Causes: Wrong issuance of thread from store, negligence of R&I supervisor, operator. No information in PPC file and communication regarding thread.

WRONG COLOR THREAD

Root Causes: Negligence of final inspector and packer. Final inspector is not inspecting the garment from inside.

UNCUT ID LABEL

Some Critical Faults

Root Causes :Using eatable things in the unit Negligence of the staff No awareness

Fault Category Critical Fault Code 459

DEAD BUGS

Root Causes : Due to not following needle issue methodDue to not using metal detector machine properly.Without replacement needle issued to operator.

BROKEN NEEDLE

Root Causes: SPI not as per requirement or standards. Machine is not properly working.

Fault Category Critical (Child) Fault Code 465

INSECURE BUTTON

Root Causes: Improper cleanliness of work places. Workers are touching their hands with their hairs during work.

LOOSE HAIR

Root Causes: Sharp edges at work place. Insects at your work place.

BLOOD STAIN

Root Causes: Negligence of machine operator & mix label provided to machine operator. No information about label or fabric content provided.

WRONG CONTENT LABEL

495 Stones Left in Pocket after Wash (Children) Critical471 Closures with Sharp Edges (Children) Critical463 Damaged/Broken Closures (Children) Critical467 Drawstring/Cord not Tacked (Children) Critical473 Improper Placement of Drawstring (Children) Critical465 Insecure Button (Children) Critical474 Unwanted Sharp Point / Sharp Edge Critical477 Improper length of Drawstring (Children) Critical488 Minimum Neck Stretch Minus (Children) Critical468 Hand Sewn Buttons/Trims (Children) Critical487 Sharp Tool Critical478 Sharp point /Sharp edge/Staples/Pins Critical409 Improper Country of Origin Label Critical445 Missing / Incorrect Tracking Label (Children) Critical454 Missing Care Instruction Label Critical447 Missing Country of Origin Label Critical994 Wrong Fiber Content Critical

Other Critical Faults

Some Packing Faults

Root Causes: Negligence of packer.

OCR STICKER MISS

WRONG SIZE GARMENT IN PACK

WRONG ASSORTMENT

WRONG SIZE UPC STICKER

fault library 2016-2017 by abdul latif (+92 3127274200)

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