Development Of An Automated Garment

Inspection System

Introduction To Artificial Intelligence

Assignment 1

PRESENTATION BY;
•Akriti Pandey
•Khushi Gupta
•Mansi Chand
•Nisha Kumari
 Introduction
 Defect in the garments industry is a common phenomenon that hampers
the smooth production rate and focus on poor quality products having an
impact on overall factory economy by:-

• Creating negative impact on costs of the product.

• Increasing nonproductive activities like rework on same garments.
• Decreasing overall efficiency.
• Increasing expenses due to fabric loss, additional uses of infrastructure,
  additional uses of workers etc.

 The defect of sewing section has a great relationship between quality

and productivity. If more defects are found after sewing, then negative
impact on costs of the product.
 Also, it has been observed that price of garment is reduced by 45% to
65% due to defects. It is imperative, therefore, to detect, identify, and
prevent these defects from reoccurring.
 Because of maintaining standard or quality of product it is mandatory to
detect the fault and find out the best solution to diminish the error.

The failure of a component, such as the seams, can result in failure of the
whole product, regardless the quality of other components or fabrics used
in the product.

The following costs for correcting of a single fabric defect during various
apparel manufacturing steps were reported.

• Spreading/Cutting $ 0.60
•During Sewing $ 12.00
•Sewing Completed $ 23.00
•Finishing Completed $ 32.00
 Idea
• Continuous image processing and analysis to
detect stitch defects

Purpose
• An automatic detection of stitch defects 

Detection stage
• After sewing of garment
Abstract

• A system is developed to do the defect inspection using computer

vision techniques and classify the detected defect.
• A method to detect and classify to obtain the type of defect.
• Evaluation of the results obtained from the system developed in real
conditions similar to industry.
Some Common Stitch And Seam Defects

These are the sewing nonconformities that have been considered for
detection.

Seam slippage:
•  Seam slippage is the pulling away or
separation of the fabric at the seam,
causing gaps or holes to develop.
• It involves warp and weft threads
pulling apart, but not yarn breakage.

Causes: Seam Slippage

This happens when the yarns in the fabric

are pulled out of the seam and are more
frequent in fabrics made from continuous
filament yarns
Seam puckering:

• Puckered seam is where the seam does not lay

flat after stitching mainly due to too much
stretching of the fabric while sewing. Shrinkage puckering

Causes:
• Uneven stretching on to plies
of fabric during sewing.
• Improper thread tension.

Types :
• Inherent puckering (structural
jamming) Machine puckering
• Tension puckering Inherent
• Machine puckering puckering
• Shrinkage puckering
 Broken Stitch

• Non-continuous sewing thread

Causes: 
• It appears due to improper trimming or
machine usage.  Broken Stitch

Uncut/ loose thread

• Extra threads or loose threads on seam

line
Causes: 
• It appears due to improper trimming or
finishing.

Uncut/ loose thread

 Improper stitch balance (301 lock-
stitches):

• The loops are seen either on the bottom

side or topside of the seam.
• This is prominent with different colored
needle and bobbin threads and also, this
defect comes where the stitch is too loose.
Cause
Improper tension of thread.

Open seam – seam failure – fabric:

• Open seam is where the stitch line is still intact

  but the yarns in the fabric have ruptured.
.
Causes:
• Improper handling of the parts of
garments.
• Improper setting and timing between
needle and looper or hook etc.
How it works ?
 START

NEW IMAGE N
Garment Inspection System AVAILABLE
?
Process Flowchart Y
IMAGE CORRECTION

DEFECT DETECTION

DEFECT N
DETECTED
?

Y
SURFACE DISCRIPTORS
CALCULATION

DEFECT CLASSIFICATION/RECORDING

N END OF
GARMENT

Y
INSPECTION REPORT GENERATION

END
 Process
• This system uses statistical approach for automated inspection of defects as the
intensity of light coming from defected regions is varied considerably as
compared to other surrounding regions.
• Each captured image is processed prior to detection process so as to remove
any projection errors, if any.

screen
• The image is converted from color to a grayscale format and smoothed for
noise attenuation. The image will be binarised. Image binarization is the
process of taking a grayscale image and converting it to black-and-white,
essentially reducing the information contained within the image from 256
shades of gray to 2: black and white.

• In this case, the object of interest is the seam and will be displayed with
black pixels, while the fabric will be labeled as background.

• The image is then processed in defect detection step to look for any
defective regions.

• A sequence of color appearances will be pursued and if an incorrect one is

detected, a defective seam/ stitch region will be revealed.
The image processing stages of straight seams detection are presented in
Figure . In this case, first step will be the image binarization . Then it lead to
defect detection which will be highlighted by cetain colour followed by colour
segmentation.

(a) (b) (c) (d)

Original image of a double seam with (a) missing stitches; (b) binarized image;
(c) color segmentation; and (d) defect detection result.
In figure , The defect consists of a seam thread break, which means incomplete
stitching. In this case, first step will be that stitches are represented by binarized
pixels . The presence of two colors per stitch is checked and points out an incorrect
seam (Figure 3(c)). Thus, The lack of seam is marked correspondingly.

(a) (b) (C)

Circular seam with thread missing stitches: (a) vent reinforcement seam
image, (b) color segmentation, and (c) defect detection.
In Figure , the circular seam is superimposed; therefore, the defect is
symbolized with red marks.

(a) (b)

A long superimposed circular seam: (a) original image, (b) detected

nonconformity.
 The following images depicts the detection of improper stitch balance.

Improper stitch Binarized image Defect detected

balance
 Detection of seam slippage

a) original image of b) Binarized image c) Defect detection

Seam slippage image
Process continued

• If any defect is present, then it needs to be classified into one the predefined
defect categories. Hence if defect is detected, the image is processed in a
texture descriptors calculation step.

• The evaluation will consist of a color sequence inspection. If the sequence is

not correct, a negative diagnosis result will be displayed as the stitch is either
incomplete or broken, either the direction is deviated.

• These descriptors are used in defect classification step. A report containing

number of defects, type of defect and defects area is generated per garment
specifying the information related to garment industry processes.
 Inspection Report

• The inspection report is then generated specifying the place of

occurrence of defect, the intensity of the defect based on the length,
width and area of the defect, number of defects in a garment. And
depending on the records, the garment quality is graded based on
the standard tolerance level already fed in the system.
Advantages
• Human inspection is the traditional means to assure the quality of fabric but
human error occurs due to fatigue and fine defects are often undetected.
Therefore, automated inspection of fabric defect becomes a natural way to
improve fabric quality and reduce labor costs.

• It helps in instant correction of small defects.

• The fabric defects inspection can take a long time with human visual
inspection that proves to be insufficient and costly.
Hence in order to reduce the cost and wastage of time, automatic fabric
defect detection is required.
Advantages
• Automatic defects detection of seams keeps the sewing process in control
and makes the final product comply with the client requirements.

• It also reduces the chances of human error.

• No breaks ; machine unlike humans, do not require frequent breaks and

refreshment.

• Greater productivity and increased efficiency

References
• https://medcraveonline.com/JTEFT/study-on-different-types-of-defects-a
nd-their-causes-and-remedies-in-garments-industry.html
• https://clothingindustry.blogspot.com/2018/03/major-sewing-defects-gar
ments.html
• https://www.hindawi.com/journals/jtex/2014/738504/
• https://www.irjet.net/archives/V5/i12/IRJET-V5I12173.pdf
• https://journals.sagepub.co
• https://apps.dtic.mil/dtic/tr/fulltext/u2/a267738.pdf
m/doi/abs/10.1177/004051759906901107

• Note: we have taken inspiration from the image processing technique that is used in automobile industry and is
yet to be incorporated in the textile industry.
THANK YOU