Defects in Woven Shirt & Prevention

1. Broken or Missing Stitches Prevention: Regularly maintain and calibrate sewing machines. Ensure operators are properly trained and monitor their work consistently. Use high-quality threads suitable for the fabric.

1. 2. Incorrect Stitch Density Prevention: Calibrate sewing machines to maintain consistent stitch density. Regularly check and adjust settings as needed. Provide thorough training to operators on stitch density requirements.

3. Fabric Puckering

1. Prevention: Use appropriate thread tension and stitch length. Ensure fabric is fed evenly through the machine. Pre-shrink fabric to prevent changes during sewing.

4. Misaligned Seams

1. Prevention: Use precise pattern cutting and marking. Ensure operators align pieces correctly before sewing. Employ quality control checks at various stages of production.

5. Untrimmed Threads

1. Prevention: Implement a strict inspection process to trim any loose threads before final packaging. Ensure operators are trained to trim threads during the sewing process.

6. Button Defects (e.g., loose buttons, misaligned buttonholes)

1. Prevention: Use high-quality buttons and thread. Ensure buttonholes are marked and sewn accurately. Perform regular checks and secure buttons properly.

1. Color Variation

1. Prevention: Use fabric from the same dye lot for each batch of shirts. Store fabric properly to avoid exposure to light and other elements that might cause fading. Maintain consistent washing and handling processes.

1. Oil Stains

1. Prevention: Regularly clean and maintain sewing machines to prevent oil leaks. Ensure operators handle fabric with clean hands and tools. Conduct regular inspections to catch and treat stains early.

1. Fabric Defects (e.g., snags, tears)

1. Prevention: Inspect fabric rolls thoroughly before cutting. Use high-quality fabric suppliers. Handle fabric carefully throughout the production process to avoid damage.

1. Uneven Hems or Cuffs

1. Prevention: Ensure accurate measurements and cutting of fabric pieces. Train operators to sew hems and cuffs evenly. Perform regular quality checks during and after the sewing process.