Fabric & Garments Faults & it’s Remedeys

SOUTHEAST UNIVERSITY
Department of textile engineering

Project on

December 28, 2013

AKH Group and Micro Fibre

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Prepared By : Mazadul Hasan
sheshir
ID: 2010000400008
13th Batch
Wet Processing Technology
Email:
mazadulhasan@yahoo.com
Southeast University

Department Of Textile Engineering
December 28, 2013

I/A 251,252 Tejgaon GMS
AKL and Dhaka Bangladesh

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Submitted To

Dr. Md. Abul Kalam Azad
Part Time Faculty
Visiting Professor
Department of Textile Engineering

December 28, 2013


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Objects of Project
• To know about the Fabric & garments faults with their
remedies.
• To know about different types of fabric inspection.
• To know about different quality parameters of fabric,
different trims & accessories.
• To know about the buyers AQL.
• To know about major or minor fabric faults & its
remedies.
• To Know about the Dyeing & Printing Faults & its
remedies.
December 28, 2013


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Introduction
Fabric Faults/Defects:
Common Defects of Fabrics during manufacturing process includes back fabric
seam impression, birds eye, bowing, broken colour pattern, colour out, colour
seamrs, crease mark, drop stitching, dye streak in printing, hole, jerk in, knots,
mixed yarn, mottled, needle line, open reed, pin holes, press off etc.
Fabric Faults are two types
1. Knitting Faults.
2. Weaving Faults.
December 28, 2013


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Knitting Faults:
A defect in the knitted fabric is an abnormality, which spoils the aesthetics i.e.
the clean & uniform appearance of the fabric & effects the performance
parameters, like; dimensional stability etc.
There are various types of defects, which occur in the Knitted fabrics of all
types, caused by a variety of reasons. The same type of defects may occur in
the fabric, due to a variety of different causes e.g. Drop Stitches, Spirality.

December 28, 2013


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Garments Faults/Defects:

Garments Defects are classified within the following categories:
Critical Defect: A serious defect that can cause harm or injury to the user
and/or result in a hazardous condition.
Major defects: A defect that falls to meet the mandatory regulations directly
affecting the usability, stability, safety and value of the merchandise or as
specified by customer buyer are considered as major defects and are generally
non repairable for example fabric hole, shading among panel, wrong
measurement, foreign yarn, dye patches etc.
Minor Defects: A defect that does not adversely affect the usability of the
product but does consists of a deviation from the original sample, and may
affect the sale of the product. Some of these defects are due to workmanship
December 28, 2013


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Knitting Faults Causes & its Remedies
Faults name

Causes

Remedy

1. Barre

Caused by mixing yarn on feed
into machine.

Proper yearn selection and
proper roller adjustment.

2. Broken Colour Pattern

Usually caused by color yarn out
of place on frame.

Proper adjustment of color and
yarn.

December 28, 2013


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Faults name

Causes

Remedy

3. Crease mark

Its create when fabric passing
through squeeze rollers in the
dyeing process. Its mainly
Occurs in tubular knits fabric.

Proper adjustment of squeeze
rollers.

4. Hole

caused by broken needle

Change the needle.

5. Needle Line

Caused by broken needle
forming distorted stitches

Replace the needle

December 28, 2013


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Faults name

Causes

Remedy

6. Runner

Usually caused by broken
needle.

Change the needle.

7. Slub (Knit fabric)

Usually caused by a thick or
heavy place in yarn

Replace the yarn cone to a
more uniform yarn cone.

December 28, 2013


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Dy eing, printing and finishing faults
Causes and Its remedy

Classification of Defects
 Major Defect
• A defect that, if conspicuous on the finished product, would cause the
item to be a second. (A "second" is a garment with a conspicuous defect
that affects the salability or serviceability of the item.
 Minor Defect
• A defect is defined as minor Defect that is not likely to reduce the
Usability of the product, but nevertheless may negatively influence the
sales.
• The minor defects can be untrimmed thread-ends, slight dirt in a nonnoticeable zone which can be removed, etc
December 28, 2013


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Faults name

Causes

Remedy

1. Barre

Its horizontal shaded band
across the width of the fabric. It
causes by the yarn mixing

proper yarn selection.

2. Bleeding

improper dye selection or poor
dye fastness.

proper dye selection.

3. Crocking

It is the rubbing off of the
color.
It may rub onto another fabric.

proper dye selection.

barre
December 28, 2013

Bleeding

Crocking
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Faults name

Causes

Remedy

4. Shading

It is generally due to uneven
tension on the fabric.

To maintain the proper tension

5. Color variation in yarn

Caused due to lack of agitation in
the dye bath

proper agitation in the dye bath.

6. Crack or miss alignment in
transfer printed fabric.

Incomplete transfer of design
from paper to fabric

Proper transfer of design.

Shading
December 28, 2013

Crack

Color variation yarn
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Faults name

Causes

Remedy

7. Creasing

Causes unleveled penetration of
dyes

To use proper dyes and
chemical or leveling agent.

8. Flushing/Wicking

Caused due to Low viscosity of
print paste

To use high viscosity of
printing past

9. Decolorized patch on fabric

Caused due to chemical spillage
on fabric. Localized excess
bleaching. Localized excess
enzyme wash.

To using spot cleaner.

Creasing
December 28, 2013

Flushing

Decolorized patch
on fabric

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Garments faults Causes and its remedy
Faults Name

Causes

Remedy

1. Misprints or off registration.

not properly cleaning of Printing
screens .

Properly Cleaning of printing
screen.

2. Grease/ Oil / dirty stains.

Oil stains generally come from
sewing machines; machines such
as over lock and flat lock machines
are more prone to have oil stains.

To use spot cleaner chemical

3. Needle damage.

using the wrong needle.

Repairing or alter the garments

4. Open or broken seams

improper handling of the cut piece
or machine

Repairing or alter the garments.

Misprint
December 28, 2013

Grease/ oil/ dirty stain.

Needle damage


Open or broken seam
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Faults name

Causes

Remedy

5. Broken stitch

improper handling of cut pieces
or improper machine usage.


6. Skipped or dropped stitches

improper handling of cut pieces
or improper machine usage.


7. Neck shape.

caused by defective cut pieces.

or use proper cut piece of
garments.

8. Sewing thread not matching.

To use improper sewing thread.

To use proper sewing thread.

Broken stitch
December 28, 2013

Skipped stitch

Neck shape

Sewing thread not
matching

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Faults name

Causes

Remedy

9. Seams not aligned at crossing
of seams.

improper handling of the cut
piece.


10.Stripes not matching.

from improper handling of cut
pieces.


11.Misplaced label

improper placement of labels
when sewing

or proper placement of the label.

Seam not aligned at
crossing of seams
December 28, 2013

Stripes not matching

Misplaced label
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Metal Detection Machine:
Metal Detection machine is a machine which is detected the metal in the
Garments. When the Garments were full completed, then it is passes throw the
finishing section. Then the Garments were packaging and it is send the final
inspection. The final inspection process is Metal Detection. The packed Garments
were passes throw the Metal Detection machine. When the machine was found
the metals, then the red button is on. Many metals such as, Pin, Needle, or any
other metals.

December 28, 2013


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Conclusion
In Bangladesh the maximum dyeing industry are knit dyeing
Industry. So these kinds of industries are often suffering by these
Faults which tend to not fulfill the target of production. As a
result the production capacity of these industries falls significantly.
These are the common faults which I have tried to find out the
causes & their Remedies against them.

December 28, 2013


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Thank U All

December 28, 2013


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Fabric & Garments Faults & it’s Remedeys

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