List of Defects Found in Sewing Section

Introduction:

Sewing is the process of attaching two fabric parts by using stitches which is made with a needle and thread. Sewing is one of the basic steps of garments manufacturing process. Also sewing section is the most significant section of a ready-made garments industry. Different types of faults or defects arise in sewing section which should be reduced to maintain the required quality of apparel. As its importance, this article has shown all the defects which produced in sewing section of garments manufacturing factory.

Sewing defects

Types of Defects Found in Sewing Section:

The following are the defects should be identified and must be made defect free in the sewing section:

Sewing Defects:

1. Needle damage: for example, thread drawn-off from the fabric or making of large hole to the fabrics.
2. Skipped stitch.
3. Thread drawn-off.
4. Seam puckering.
5. Wrong stitch density.
6. Uneven stitch.
7. Staggered stitch.
8. Defected stitch.
9. Oil spot or stain.

Seaming Defects:

1. Uneven width.
2. Uneven seam line.
3. Not secured by back stitch.
4. Twisting.
5. No matching of check or stripe.
6. No matching of seam.
7. Unexpected materials are attached with the sewing.
8. Not sewn by matching face side or back side of fabrics.
9. Use of wrong stitch type.
10. Wrong shade matching of sewing thread.

Assembly Defects:

1. Defected finished components by size i.e. imperfect size and shape of finished components.
2. Imperfect garments size.
3. Use of wrong ticket.
4. Missing of any parts or predetermined design of garments.
5. Imperfect alignment of components i.e. button, hook, and so on) in proper place.
6. Wrong placing or creasing of interlining.
7. Looseness or tightness of interlining.
8. Folding of any parts of garments that is seen to bad appearance.
9. Shade variation of garments.
10. False direction of fabric parts in the garments.
11. Imperfect matching of trimmings in the garments.

Speech from the writer:
If you read this article with full concentration then you can easily answer the below questions in the interview:

1. Mention different types of faults produced in sewing section.
2. Point out the major faults found in sewing section of garments factory.
3. List of sewing defects produced in sewing section of RMG industry.
4. List of seaming defects produced in sewing section of apparel industry.

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Sampling process in apparel industry

Sampling Process

Sampling is very important in apparel industry because the buyers usually place orders after reviewing the quality of the samples. Buyers also require different types of samples after placing orders. Apparel merchandisers should have to be well acquainted of different stages of garments sampling to execute an order. Sometimes same samples are known in different names. Let us see what types of samples the merchandisers have to send to buyers.

Proto sample, prototype sample, development sample, design sample:

The first physical version of sample garment in product development stage prepared as per the artwork. This sample is made to see the design mainly. Garments material and color are not considered for this sample.

Fit Sample:

Fit is prepared following actual measurement. This sample is made to test the fitting. Live model is used to verify garment fitting.

Counter sample, style reference sample:

The sample that is prepared following another sample received from buyer. This sample is made to see the workmanship and to justify the factory skill. Garments material and color are not considered for this sample.

Mock up sample

Part of the garment (sleeve, collar, front/back panel etc.) not complete garment. It is made as per buyer’s requirement to serve particular purpose.

Salesmen samples, promotional sample, Photo shoot samples:

The samples are prepared with actual color and yarn/fabric to be worn by the models on the event of photo shoot for catalog. Buyer makes comments on fitting requirements and problems in the measurements with the photo attachments. Buyer also held meeting/meetings with his/her customer(s)/retailer(s) for their feedback. Color wise order quantity, size etc. are confirmed to place order. Actual material and color are mandatory for this sample.

Approval sample:

Sometimes it is required to make approval samples when first technical spec is revised. It is made to ensure that buyer’s requirement is conformed and to avoid any confusion/dispute at the time of final production.

Size set samples:

Size set samples are made to ensure measurement of each size. Usually size set samples are made covering all color combos.

Pre-production (PP) samples:

The factory makes pre-production (PP) samples with the actual material when bulk fabric and accessories are in house for production. The samples are prepared to ensure buyer that the bulk materials are in house for production.

Production samples:

The factory send production samples to ensure buyer that the bulk production is going on produced as per buyer’s requirement following technical specifications and approved sample. Buyer wants to be assured that correct material is sourced and line workmanship conformed with the quality level.

Top of Production (TOP) Samples, Online samples:

TOP/Online samples are the samples that are taken when the first production is online. Usually some buyers ask for TOP sample to cross-check if the factory is following Pre-Production sample.

Shipment sample, ship sample, fulfillment sample:

The samples that reflects the final shipment are shipment samples. The samples ensure that goods have been shipped as per the samples.

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Process Flow Chart of Apparel Merchandising

Merchandising:
Merchandising is the department which mediates marketing and production departments. It is the methods, practices, and operations used to promote and sustain certain categories of commercial activity. So it is a very valuable department in apparel industry.

Apparel merchandising

Process Flow Chart of Merchandising

Received art work and size specification for development of the sample
↓
Making development sample
↓
Consumption (from CAD) & costing
↓
Meeting with buyer for price & order confirmation and LC received
↓
Lab-dip approval
↓
Making different types of sample (as per buyer requirement) for approval
↓
Making pre-production (pp) sample with all actual
↓
Yarn booking
↓
Bulk fabric order
↓
Accessories order
↓
After approval of pp sample arrange pp meeting
↓
Start bulk production
↓
Arrange an inline inspection
↓
Send a test sample to 3rd party testing center
↓
After completion of bulk production arrange final inspection
↓
Arrange all commercial papers for shipment
↓
Shipment
↓
Sending documents to Buyer
↓
Payments receive from Bank

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Different Types of Fusible Interlining Used in Garment Industry

Fusible Interlining:

Fusible interlining is one kinds of interlining which is fixed with the garment components by applying heat and pressure for certain period of time. Various types of fusible interlining which are significantly used in apparel manufacturing industry has mentioned in this article.

Classification of Fusible Interlining:

Fusible interning is classified into six types. Those are-

1. PVC coated interlining,
2. PVA coated interlining,
3. Polyethylene coated interlining,
4. Polyester coated interlining,
5. Poly amide coated interlining,
6. Poly propylene coated interlining.

All the above types of fusible interlining have explained in the below:

1. PVC coated fusible interning:

• PVC (poly vinyl) coated is used as resin coating.
• PVC coated is suitable for both dry cleaning and washable garments.
• It is significantly used for making the coat type garments.

  

  PVC coated interlining

2. PVA coated fusible interlining:

• PVC (polyvinyl acetate) is used as resin coating.
• Polyvinyl acetate coated interlining is not dry cleanable and it has limited wash ability.
• Low pressure and temperature is required here which is used between the leather and far materials.
• Here, the resin is normally in the form of a continuous plasticizing coating on the base fabric.
• PVA coated fusible interlining is rarely used in garments manufacturing industry.

  

  PVA coated interlining

3. Polyethylene coated fusible interlining:

• Here, polyethylene is used as resin coating.
• The impact of varying the density of the resin is to give a greater resistance to dry cleaning solvents and a higher softening point with increasing elasticity.
• Polyethylene coated fusible interlining is used in collar, cuff of shirt.
• The fabric which is attached with this type of interlining can be washed in water.

  

  Polyethylene coated interlining

4. Polyester coated fusible interlining:

• In case of polyester coated fusible interlining, polyester is used as resin coating.
• Here, polyester resins are used in washable dry cleanable garments. Because polyester is less water absorbent than poly amide.
• Polyester coated fusible interlining can be used in all types of garments.
• This is termed as ideal interlining.
• It is available in market though costly in price.

  

  Polyester coated interlining

5. Poly amide coated fusible interlining:

• In case of Poly amide coated fusible interlining, poly amide is used as resin coating.
• Poly amide coated interlining is widely used in dry cleaning solvents.
• Higher temperature fusing is done for the garments which are washed at 60 degree temperature.

  

  Poly amide coated interlining

6. Polypropylene coated fusible interlining:

• Polypropylene coated fusible interlining is similar to the properties of polyethylene coated interlining.
• Comparatively higher temperature fusing is done here.
• The fabric which is attached with this interlining can be washed with the water.

  

  Polypropylene coated interlining

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Simple Automatic Sewing Machine Used in Apparel Industry

Introduction:

Sewing machine is one of the most important equipment in garments manufacturing industry. Simple automatic sewing m/c is one of the types of sewing machine. Simple automatic sewing m/c includesbutton attaching sewing machine, button hole sewing m/c and bar-tack sewing m/c. This article has presented those automatic sewing machines with their features.

Simple Automatic Sewing Machine:

Some machines are found to sew for special purposes such as button hole making, button attaching, bar-tack creating and so on. In these machines, the predetermined work is done by cyclic order that is why called simple automatic is sewing m/c.

Various Simple Automatic Sewing Machine Used in Garment Industry:

The following are the description of some simple automatic sewing machines:

1. Button hole sewing machine:

Button hole sewing machine

• It is a simple automatic sewing m/c.
• Easy adjustment of hole size and stitch density are facilated here.
• For heavy fabric, hole is cut before sewing.
• For lighter fabric, hole is cut after sewing.
• Special type of sewing thread is used for sewing.
• To raise the stitch is called gimp.
• Stitch type: lock or chain stitch may be used.

2. Button attaching sewing machine:

Button attaching sewing machine

• It is a simple automatic machine.
• Button positioning can be automatic.
• Sewing is done according to the hole in button and may be cross or parallel.
• Automatic feeding of the button.
• Stitch type: lock or chain stitch may be used.

3. Bar-tak sewing machine:

Bar-tak sewing machine

• Simple automatic sewing m/c.
• It is used for heavy fabric sewing.
• It is a cyclic operation.
• It is used where the garments in high pressure such as belt loop, pocket corner.

Speech from the writer: If you read this article attentively then can answer the below questions easily in the interview:

1. What do you understand by automatic sewing m/c?
2. Mention the key features of button hole sewing m/c.
3. Mention the characteristics of button attaching sewing m/c.
4. Point out the features of bar-tack sewing m/c.

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List of Trimmings, Accessories Needed for Making Shirt, Pant

List of Trimmings and Accessories Required for Making Shirt, Trouser and Jacket

Introduction:

Trimmings and accessories both are very much important for manufacturing the garments. There are different types of trimmings and accessories used for making shirt, trouser or pant and jacket in readymade garments industry. This article has shown those required trimmings for Shirt, Trouser and Jacket in differently.

Trimmings and Accessories used in garments

Trimmings:

Without fabrics, the materials which are used in a garment during the making of garments are called trimmings. A trimming can also be a narrow fabric used as decorative or functional edging on apparel or furnishing fabrics. Some trimmings can be seen from the outside of garments which are used outside the garments and some are not seen which are used inside the garments.

Accessories:

Accessories are those materials which are not attached with the apparel. It can be explained in other way, accessories are those materials which are not used during manufacturing the garments, only used for finishing and packing the garments.

List of Trimmings Required for Making Shirt:

1. Sewing thread,
2. Button,
3. Lining,
4. Interlining,
5. Motif,
6. Label i.e. main label, care label, size label, price label and composition label.

List of Trimmings Required for Making Trouser or Pant:

1. Sewing thread,
2. Lining,
3. Button,
4. Zipper,
5. Label i.e. main label, care label, size label, price label and composition label.

List of Trimmings Required for Making Jacket:

1. Button,
2. Sewing thread,
3. Lining,
4. Motif,
5. Zipper,
6. Label i.e. main label, care label, size label, price label and composition label.

List of Accessories Required for Making Shirt, Pant and Jacket:

1. Neck board,
2. Back board,
3. Plastic collar insert,
4. Hang tag,
5. Ball head pin,
6. Tissue paper,
7. Poly bag,
8. Silica gee bag,
9. Carton,
10. Carton sticker,
11. Safety sticker,
12. String,
13. Hanger,
14. Butterfly,
15. Collar stay,
16. Price ticket,
17. Gum tape,
18. Bruss pin,
19. Tag pin,
20. Safety pin,
21. Buckle,
22. Size strip,
23. Pocket flasher,
24. Both side tape,
25. Plastic clip.
    

5S Principles on Garments Productivity

5S Principles on Garments Productivity

Introduction:

To achieve higher garments productivity 5-S principles play an important role in garments manufacturing sector. In today’s ready made garments business, most of the factories are regularly maintained 5S principle for producing higher number of quality garments. As its importance, today I will present here the details discussion on 5S principles.

5S Principle Cycle

What is 5S Principle?

Japanese management tries to instill in the brains of employees some basic principles of work which are known in Japan as 5S principles. It is very effective in business and garments production management, which proved not only in Japan but also outside the Japan.

5S principles are mentioned in the below:

1. Seiri: Clear unnecessary materials,
2. Seiton: Ensure good house keeping,
3. Seiso: Keep cleaning the machines, workplace, etc.
4. Seiketsu: Pursue right standard,
5. Shitsuke: Train your personnel.

Impact of 5S Principles on Apparel Production:

Influence of 5S principles on garments productivity have discussed in the following:

1. Seiri: Clear unnecessary materials:

This principle contains the below matters:

• Remove unused and unusable materials,
• Clear defective products,
• Clear superfluous things,
• Remove idle equipment and tools.

All these result in clean and tidy workplace and better work environment.

2. Seiton: Ensure good house keeping:

This includes in arranging right materials at right place for quick access and disposal. This leads to better organization of materials and congenial work environment. Seiton results in less time in accessing materials and disposing them for garments production. This result creates the opportunity for higher garments productivity.

3. Seiso: Keep cleaning the machines, workplace, etc:

This principle includes the below matters-

• Seico leads to machinery in good condition,
• Neat and clean work place i.e. fabric and garments not dirty or spoiled,
• Rework or re-process,
• Good environment,
• Higher performance in productivity and quality.

4. Seiketsu: Pursue right standard:

Appropriate work standard leads to better employee performance, higher quality and productivity.

5. Shitsuke: Train your personnel:

This principle includes the below matters-

• Training leads employees to achieve higher skill and workmanship,
• Higher dedication and motivation,
• Better work habits,
• Higher worker performance,
• Higher garments productivity, and
• Perfect quality.

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