APPAREL QUALITY MANAGEMENT

SUBMITTED BY:

SIVANI JAYANTH

BFT/17/1109
Quality Control Tools representing defect in a Shirt

CHECK SHEET:

SL.NO TYPE OF DEFECTS NO. OF DEFECTS

.

1 Broken stitch IIIII

2 Needle hole mark III

3 Raw edge out II

4 Over stitch III

5 Skip stitch IIII

6 Un cut thread IIIII II

7 Uneven stitch IIIII I

8 Puckering III

A check sheet is nothing but a form used to collect data in such a way that it makes not only the
collection of data easy, but also the analysis of that data automatic. Each mark in the check sheet
indicates a defect. The type of defects, number of defects, and their distribution can be seen at a
glance, which makes analysis of data very quick and easy. Check sheets provide a logical display of
data that are manually derived and yield results from which conclusions can be easily drawn.
HISTOGRAM:

Histogram is also a bar chart. It is a graphical chart based on numeric value for showing frequency
distribution of database. People become confused among Histograms and Bar Charts. A histogram is
used for continuous data, where the bins represent ranges of data, while a bar chart is a plot of
categorical variables. Some authors recommend that bar charts have gaps between the rectangles to
clarify the distinction.

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CAUSE & EFFECT DIAGRAM

A cause & effect diagram is a simple but very effective tool that helps to identify, sort, and display
potential or real causes of a specific problem or quality characteristic. It can also be used to
graphically illustrate the relationship between a given outcome and all the factors that influence the
outcome. Because of its function of relating causes to their effect, it is referred to as a cause-and-
effect diagram. It is also called a fishbone diagram because the design of the diagram looks much like
the skeleton of a fish. It is also known as Ishikawa diagram.

MACHINE/ MAN
EQUIPMENT

Needle plate, pressure foot Incorrect needle eye position

may be rusty/have sharp
edges
Faulty feed dog
BROKEN STITCH

Weak Thread
 Incorrect tension of sewing thread

Incorrect threading

MACHINE/ MAN
EQUIPMENT

Needle edges might be Unskilled worker, Doing wrong

broken or curved stitch and removing

Faulty feed dog

NEEDLE HOLE MARK

High GSM of fabric.

Incorrect tension of sewing thread
Wrong needle- thread-fabric combination

METHOD MATERIAL

MAN

Not removing the previous

stitch and stitching over.

MACHINE/ Over stitch

MAN
EQUIPMENT
Unskilled worker, Doing wrong
Guidelines not given properly
Needle edges might be
stitch and removing
broken or curved

Faulty feed dog

METHOD NEEDLE HOLE MARK

High GSM of fabric.

Incorrect tension of sewing thread
Wrong needle- thread-fabric combination
 MACHINE/
MAN
EQUIPMENT

Needle deflection or bending Operator inefficiency

Tension variation in bobbin, thread

Skip stitch

Small needle size

METHOD

MAN

Operator speeding up machine

rapidly

Operator holding back or pushing fabric

through in variance with correct machine
speed

Uneven stitch
 MACHINE/ MAN
EQUIPMENT

Thread trimmer not working

Negligence

Uncut thread
endings
Pulling and breaking instead of
cutting

Incorrect finishing

METHOD

MAN

Unskilled

RAW EDGE
VISIBLE

Improper folding

METHOD

MAN
MACHINE/
EQUIPMENT
Incorrect handling
Dirty / Rusty eyelets &
thread guides
SUGGESTION

 Broken Stitch: Make sure that the needle thread and bobbin thread tension is right.
 Needle hole mark: Make sure the needle is not bend or broken, the fabric thread needle
combination should be right
 Over stitch: Make sure the guidelines to stich are followed and unwanted stitch is removed.
 Skip stitch: make sure that the cloth is not held tight and tension of bobbin and thread is
correct.
 Uneven Stitch: Make sure the operator follows the guideline and they do not speed up
rapidly.
 Un cut thread: Make sure the guidelines for finishing is followed properly and the thread is
cut.
 Raw edge visible: Make sure the cutting is correct and while stitching the folding is right.
 Puckering: Make sure the tension and thread and needle is right , SPI is correct and thread is
not pulled out unnecessarily.