Problems analyes & corrective action

1 | P a g e E t h i o p i a
Engr Mizanur Rahman. Fabrics Finishing Expert.
MAA Garment & Textiles Factory
(Kebire Enterprises PLC)
PO Box 1976, Quiha, Mekelle, Ethiopia.
Year of 2015-2017
Reporting Date: 5th
September 2017
Mohammad Mizanur Rahman
Fabrics Finishing Expert (Manager)
Cell: +251 962 600 055
Email: mizan5379@yahoo.com
Skype: mizan_mehben

Basic information of Reporter:-
1. Qualification –
A. SSC (Science)- 1st Class
B. HSC (Science)- 1st Class
C. Diploma in Textile Engineering (Textile Chemistry)- 1st Class
D. BSS (Political Science)- 2nd Class
E. B Sc in Textile Engineering (Textile Chemistry)- GPA-3.05 out of 4
F. MBA (Management)- 2nd year Study
2. Working Skills: Top of the Ten in the Bangladesh this three Factory
& Modern Technology with software basis,
A. Fakir knitwear’s Ltd
Asst Manager (Dyeing & Finishing)
Working duration: 9 years
Capacity: 45 tons
Machines: Dyeing- Thies, Fongs, Acme, PMM,
Finishing- Bruckner, ACC, Lafer, Ferraro
Brush, Peach Finish, Sharing, Shinging M/c Available
B. Epyllion Knitex Ltd
Manager (Finishing & Quality)
Capacity: 35 tons
Machines: Dyeing- Thies, Canlar, TDM
Finishing- LK&LH, Monforts, ACC, Tubetex, Ferraro, Lafer,
Suntex, Corino,
Brush, Peach Finish, Sharing, Shinging M/c Available
C. Chaity Composite Ltd
Senior Manager (Fabrics Finishing)
Capacity: 45 tons
Machines: Dyeing- Then, Thies
Finishing- Bruckner, LK&LH, Ferraro
Brush, Peach Finish, Sharing, Combing, Tumble dryer M/c

Selection for Ethiopia:
DBL Group (Bangladesh)
(Top of the ten in Bangladesh)

Follow up report:
 Knitting
 Batch Preparation
 Dyeing
 Fabrics Finishing
 Fabrics Quality
 Cutting
 Sample

 Follow up report of Knitting:
A. Count Selection
B. Drop Needle/ Stitch
C. Barriness/ Patta
D. Broken Ends
E. Yarn Missing
F. Count Maxing
G. Jumping
H. Contamination
I. Lycra Missing
J. Oil Line/Stain
K. M/c Dia selection
L. Stitch length
M. Folder/ Dia Mark
N. Yarn Streaks
O. Sinker Line
P. Pin Hole/Knitting Hole
Q. Spirality
 Follow up report of Batch Preparation:
A. Lot Maxing
B. Dia Maxing
C. Wrong information
D. Weight Not right
E. Proper Stitch
F. Follow Needle drop/Slitting Mark
Note: About the mansion that is
common problems in textile sector,
so we mansion also how to solve
easily.

 Follow up report of Dyeing:
A. Wrong Shade unload
B. Uneven
C. Dark Mark
D. Dyeing patches
E. Running shade/ Shade Variation
F. Roll to Roll Shade Variation
G. Tonal Variation/ Batch to Batch Variation
H. Body to Rib not Match
I. Crease / Rope Mark
J. Hole
K. Color fastness
L. Rubbing
M. Surface Hairiness
N. Entanglement
O. GSM Effect
P. Curling
Q.Strength Less/ fabrics Damage
 Follow up report of Fabrics Finishing:
A. Wrong Slitting
B. Crease Mark
C. Width Variation
D. Middle Loose
E. Pin Hole in selvedge
F. Hole
G. White Mark
H. Softener Mark
I. Shrinkage
J. Spirality
K. Skewing
L. Dirty Spots
M. GSM Variation with in roll
N. Shade Variation
O. Bowing

P. Elephants Skin
Q. Lycra Fabrics
i. GSM Variation with in roll
ii. Within roll 1st & last GSM variation
iii. GSM low after dyeing
iv. Roll to roll GSM variation
v. GSM up down after Finish
R. Stenter M/c Speed
 Follow up report of Fabrics Quality:
A. Inspection Reports
B. Dirty Spots
C. Hole
D. Running Shade
E. Online inspection
F. Off Line inspection
G. Grouping Delivery
H. County wise delivery
 Follow up report of Cutting:
A. QC reports follow
B. Group pattern
C. Wastage reduce
D. Width wise marker

Defect, Causes & Remedies:-
1. Crease Mark:
A. Causes:
i. From Padder (If proper not open uncurler Roller)
ii. Pin out from stenter m/c
iii. If not use leading cloth in time in stenter m/c rather than ropes
iv. From Dyeing (If ropes stage dyeing)
v. High Yarn Tension & More tied Knitting
vi. If edges not proper stitch and knots pass from corino
B. Remedies:
i. Slitting, Stenter & Compacting starting time reject fabrics Stitch.
ii. Operator all time actively follow up
iii. Dyeing time up to mark use Anti-Creasing Agent
iv. Yarn tension less from knitting
2. Width Variation.
A. Causes:
i. Stenter M/c setup change within one batch
ii. Grey fabric of the same lot, knitted on different makes of Knitting
Machines, having varying number of Needles in the Cylinder.
iii. Pin selvedge controller auto not proper work
iv. If not proper stitch before stenter m/c
B. Remedies:
i. Same setup width Full batch Finish
ii. The whole lot of the grey fabric should be knitted on the same
make of knitting machines
iii. selvedge controller should work auto
iv. proper stitch each rolls
v. Stenter m/c running time must be actively work

3. Wrong Slitting.
A. Causes-
i. If auto cutter sensor not proper work
ii. Proper Not sewing
iii. If drop needle not visible
iv. Operator not active
B. Remedies-
i. Auto cutter sensor should be in proper Working condition
ii. Proper Stitching with drop needle
iii. Operator carefully M/c operating
4. Folder/ Dia Mark.
A. Causes-
i. Mainly Lycra & High GSM fabrics
ii. High pressure of the fabric Take Down rollers of the Knitting machine
on the grey fabric is one of the main causes
B. Remedies-
i. Adjust the gap between the two rolls as per the thickness of the
fabric sheet
ii. Fabrics cutting/open from knitting (option)
iii. After knitting fabrics keeping relax stage
5. Middle Fabric Loose.
A. Causes-
i. If actual width not finish
ii. Adjust Fan pressure bottom and top
iii. Delivery tension not adjusted
B. Remedies-
i. Should be Actual with finish
ii. Adjusted delivery tension

6. Pin Hole in selvedge.
A. Causes-
i. Selvedge Auto controller not proper work
ii. Operator not active
iii. Needle ledge (pins) damage
B. Remedies-
i. Selvedge Auto controller proper work
ii. Operator carefully M/c operating
iii. Needle ledges should be inspected regularly and replace if
damage
7. Hole (GSM & Shade Check)
A. Causes-
i. More cutting for GSM & Shade samples
ii. Chemical dosing not proper (Peroxide & Caustic)
iii. More Enzyme
iv. Operator not active
B. Remedies-
i. Near of sewing GSM & Shade cutting
ii. Every step check pH & Control
iii. Proper chemical dosing
8. Pin hole/Knitting Hole
A. Causes-
i. Uneven yarn/ More Thick & Thin
ii. More Naps
iii. Uneven twist
iv. TPI less from Standard
v. Knitting m/c not properly clean
vi. M/c speed more from standard
vii. Brocken needle
viii. Uneven tension
B. Remedies-
i. Control Thick & Thin
ii. Even twist
iii. Make standard TPI
iv. Knitting m/c properly Clean

v. Speed control
vi. Check Brocken Needle
9. Hole from dyeing
A. Causes-
i. Improper Caustic solution/ dosing
ii. H2O2 improper dosing
iii. In bath more time keeping
B. Remedies-
i. Properly solution & time dosing
ii. In bath not keep more time
iii. pH control
iv. H2O2 properly dosing
10.Shrinkage.
A. Causes-
i. If Actual width not finish
ii. High Stresses & strains exerted on the fabric, during Knitting, Dyeing
&Processing & the fabric not being allowed to relax properly
iii. Not Proper Count Use
iv. Not Right Stitch Length
v. Tension on fabric during finishing
B. Remedies-
i. Should be Actual width finish
ii. Give maximum overfeed to the fabric, during the processing, on the
Stenter,& Compactor
iii. Proper Count Use
iv. Right Stitch Length
v. Minimize tension during processes (corino, stenter)
11.Spirality.
A. Causes-
i. Need proper Angle.
ii. Appropriate Yarn TPI/ High TPI. of the Yarn
iii. Knitting more feeder use
iv. Uneven Fabric tension on the Knitting machine
v. Unequal rate of Fabric feed on the Stenter & Compactor
vi. If not actual width finish

B. Remedies-
i. Auto use Weft straightener (Mahlo)
ii. Use the yarns of the recommended TPI level for Knitting
iii. Ensure uniform rate of feed of the dyed fabric on both the edges
while feeding the fabric to the Stenter & Compactor machines
iv. Actual width finish
v. Knitting feeder use less
12.M/c down time. (Finishing)
A. Causes-
i. Color wise not setup
ii. Clean time take more time
iii. If before stenter not proper prepare batch
B. Remedies-
i. Color wise batch setup
ii. Batch to batch prepare before end the batch
iii. Maximum people engage people
13.White Mark.
A. Causes-
i. If any friction.
ii. After slitting if selvedge dry.
iii. If not proper wash in dyeing.
iv. pH not control
v. Hard water / More iron in water
vi. Soda Effect
vii. Salt effect
B. Remedies-
I. After slitting urgently dry
II. pH proper control
III. proper wash in dyeing
IV. Control water hardness
14.Dirty Spot.
A. Causes-
i. Before unload from dyeing m/c trolley not properly clean
ii. M/c properly not clean (slitting, stenter, compactor)
iii. Fabrics handle not carefully

B. Remedies-
i. Trolley should be clean before unload
ii. Fabrics handle carefully
iii. M/c properly clean
15.Color Variation in Finishing.
A. Causes-
i. Stenter M/c not same speed runs
ii. If Suddenly m/c Stop
iii. Squeeze Roller Pick up % side to side Different
iv. If Stenter m/c side to side Temperature Difference
v. Stenter m/c Circulation not proper
B. Remedies-
i. Should be m/c run same speed
ii. Stenter m/c Circulation proper
iii. Check pickup %
16.Color Variation from Dyeing.
A. Causes-
i. Not Proper color dosing
ii. Wrong Dyes Selection
iii. Color Combination wrong
iv. Pre-treatment not good/ Absorbency not good
v. Entanglement in Machine
vi. pH not control
vii. Nozzle to nozzle length Variation
B. Remedies-
i. Proper color dosing
ii. pH control
iii. Rope length same every nozzle
iv. Real Speed should be same

17.Drop Stitches (Holes):
A. Causes-
i. High Yarn Tension
ii. Yarn Overfeed or Underfeed
iii. High Fabric Take Down Tension
iv. Defects like Slubs, Naps, and Knots etc.
v. Incorrect gap between the Dial & Cylinder rings.
B. Remedies-
i. Ensure uniform yarn tension on all the feeders with a Tension
Meter.
ii. Rate of yarn feed should be strictly regulated as per the required
Stitch Length.
iii. The fabric tube should be just like a fully inflated balloon, not too
tight or too slack.
iv. The yarn being used should have no imperfections like; Slubs,
Naps & big knots etc.
v. The gap between the Cylinder & the Dial should be correctly
adjusted as per the knitted loop size.
18.Barriness /Patta/ Yarn Variation-
A. Causes-
ii. Count Variation
iii. Mixing of the yarn lots
iv. Package hardness variation
B. Remedies-
i. Ensure uniform Yarn Tension on all the feeders
ii. The average Count variation in the lot should not be more than
+ 0.3
iii. Ensure that the yarn being used for Knitting is of the same Lot.
iv. Ensure that the hardness of all the yarn packages is uniform using
a hardness tester.

19.Contamination:
A. Causes-
i. Presence of dead fibers & other foreign materials, such as; dyed
fibers, husk &synthetic fibers etc.
ii. Dyed & other types of fibers flying from the adjacent Knitting
machines cling to the yarn being used for knitting & get
embedded in the Grey Fabric.
B. Remedies-
i. Use rich fiber mixing for the yarns to be used for knitting in order
to have less dead fibers appearing in the fabric.
ii. Rigid control measures in the Blow Room to prevent the mixing of
foreign matters in the Cotton mixing
iii. Segregate the Spinning & Knitting Machines, with Plastic Curtains
or Mosquito
iv. Nets, to prevent the fibers flying from the neighboring machines,
from getting embedded in the yarn / fabric.
20.Needle Line:
A. Causes-
i. Bent Latches, Needle Hooks & Needle stems
ii. Wrong Needle selection (Wrong sequence of needles, put in the
Cylinder or Dial)
B. Remedies-
i. Inspect the grey fabric on the knitting machine for any Needle
lines
ii. Check the Needle filling sequence in the Cylinder / Dial grooves
(tricks).
21.Broken Needles/ Laddering:
A. Causes-
ii. Bad Setting of the Yarn Feeders
iii. Old & Worn out Needle set
iv. Cylinder Grooves are too tight restricting needle movement
v. Breakage of hook or butt in needle.
B. Remedies-

i. Ensure uniform & the right Yarn tension on all the feeders.
ii. Keep the recommended gap between the Yarn Feeders & the
Needles.
iii. Periodically change the complete set of needles.
iv. Remove fly or blockage from groove.
v. Replace defective needle.
22.Sinker Line:
A. Causes-
i. Bent or Worn out Sinkers
ii. Sinkers being tight in the Sinker Ring grooves
B. Remedies-
i. Replace all the worn out or bent sinkers causing Sinker lines in the
fabric.
ii. Sinker lines are very fine & feeble vertical lines appearing in the
fabric
iii. Remove the fibers clogging the Sinker tricks
23.Oil Line/Stain:
A. Causes-
i. Fibers & fluff accumulated in the needle tricks which remain
soaked with oil.
ii. Excessive oiling of the needle beds.
B. Remedies-
i. Fibers accumulated in the needle tricks cause the oil to seep into
the Fabric
ii. Some lubricating oils are not washable & cannot be removed
during Scouring
iii. Remove all the Needles & the Sinkers of the machine
periodically
iv. Clean the grooves of the Cylinder & Dial of the machine
thoroughly with petrol.
v. Blow the grooves of the Cylinder Dial & Sinker ring with dry air
after cleaning.

24.Broken Ends:
A. Causes-
ii. Yarn exhausted on the Cones.
B. Remedies-
i. Ensure correct yarn tension on all the feeders.
ii. Ensure that the Yarn detectors on all the feeders are working
properly.
iii. Depute a skilled & alert machine operator on the knitting
machine.
25.Yarn Variation:
A. Causes-
i. Yarn lot mix-up
ii. Count mix-up
iii. Tension variation
B. Remedies-
i. Conform yarn lot & Count
ii. Every Feeder should be same tension
26.Bowing:
A. Causes-
i. Uneven distribution of tensions across the fabric width while
dyeing or finishing the fabric.
B. Remedies-
i. Bowing can be corrected by reprocessing the fabric by feeding
it from the opposite end.
ii. A special machine (MAHLO) is also available for correcting the
bowing in the knitted fabrics.
27.Dyeing Patches:
A. Causes-
i. Inadequate Scouring of the grey fabric is one of the primary
causes of the dyeing patches.
ii. Improper leveling agent is also one of the causes of dyeing
patches.
iii. Correct pH value not maintained.

iv. Dyeing machine stoppage due to power failure or the fabric
entanglement in the dyeing machine is a major cause of the
dyeing patches.
B. Remedies-
i. Scour the grey fabric thoroughly to remove all the impurities from
the fabric before dyeing
ii. Use appropriate leveling agents to prevent patchy dyeing.
iii. Maintain the correct pH value during the course of dyeing.
iv. Use a power back up (Inverter) for the dyeing operation to be
completed uninterrupted.
28.Softener Mark:
A. Causes-
i. Softener not being uniformly dissolved in water
ii. If pH not control
B. Remedies-
i. Scour the grey fabric thoroughly to remove all the impurities from
the fabric before dying.
ii. Ensure that the softener is uniformly dissolved in the water &
doesn’t remain dissolved as lumps or suspension
iii. Use the right softener & the correct procedure for the
application.
iv. Maintain the correct pH value of the softener before
application.
29.Stains:
A. Causes-
i. Dyeing Machine not cleaned thoroughly after dyeing a lot.
ii. Grease & Oil stains from the unguarded moving machine parts
like; Gears Shafts Driving Pulleys & Trolley wheels etc.
iii. Fabric touching the floors & other soiled places during
transportation, in the rolleys.
iv. Handling of the fabric with soiled hands & stepping onto the
stored fabric with dirty feet or shoes on.

B. Remedies-
i. Wash & clean the dyeing machine thoroughly after dyeing every
dye lot.
ii. Follow the dyeing cycle of Light- Medium- Dark shades & then
the reverse the cycle while dyeing the fabric
iii. All the lubricated moving machine parts should be protected
with safety guards
iv. Make sure that the fabric is neatly packed in or covered with
Polythene sheets while transporting or in storage.
v. Handle the fabric carefully with clean hands & do not let
anyone step onto the stored fabric.
30.Poor Color Fastness:
A. Causes-
i. Dyeing recipe i.e. the poor fixing of the dyes is a major cause of
color fading.
ii. Using the wrong combination of colors in a secondary or tertiary
shade.
iii. Use of strong detergents & the quality of water are also the
common causes for color fading
iv. Prolonged exposure to strong light will also cause the colors to
fade.
v. High level of acidity or alkalinity in the perspiration of individuals
also causes color fading.
B. Remedies-
i. Use the correct dyeing recipe i.e. the appropriate leveling, fixing
agents & the correct combination of dyes.
ii. Follow the wash care instructions rigidly.
iii. Use mild detergents & soft water for washing the garments
iv. Don’t soak the garments for more than 10- 15 minutes in the
detergent prior to washing
v. Turn the wet garments inside out while drying.
vi. Dry in shade & not in direct sunlight.
vii. Protect the garments against prolonged direct exposure to
strong lights (showrooms or exhibitions etc.

31.Shade Variation:
A. Causes-
i. Shade variation can be as a result of mixing of the, fabrics of two
different lots.
ii. Shade variation is also caused, by the variation in the process
parameters i.e. Time, Temperature & Speed etc. from one fabric
roll, to the other.
iii. Shade variation can appear to be, in fabrics with GSM variation,
caused due to the uneven stretching, unequal fabric overfeed
% etc.
B. Remedies-
i. Ensure that the grey fabric used for one shade is knitted from the
same lot of the yarn.
ii. Ensure that the same process parameters (Width, Overfeed,
Temperature &Machine Speed etc.) are used for each roll of a
Dye lot.
32.Tonal Variation:
A. Causes-
i. Wrong Dyeing recipe
ii. Wrong leveling agent selection or wrong dyes combinations
iii. Improper fabric Scouring
iv. Impurities like Oil & Wax etc. not being completely removed in
Scouring
v. Level dyeing not being done due to the inappropriate leveling
agents
vi. Variation in the process parameters, e.g. Temperature, Time &
Speed etc.
B. Remedies-
i. Use appropriate leveling agents to ensure uniform & level dyeing
ii. Scour the grey fabric thoroughly to ensure the removal of all the
impurities.
iii. Ensure that the whole lot of the dyed fabric is processed under
uniform process parameters.

33.GSM Variation :
A. Causes-
i. Roll to roll variation in the, process parameters, of the fabric, like;
Overfeed &Width wise stretching of the dyed fabric, on the
Stenter & Compactor Machine.
ii. Roll to roll variation in the fabric stitch length.
B. Remedies-
i. Make sure that all the fabric rolls in a lot, are processed under
the same process parameters.
ii. The Knitting Machine settings, like; the Quality Pulley diameter
etc. should never be disturbed.
34.Dark Mark:
A. Causes-
i. Mainly crease mark is the dark Color fabrics showing dark line.
ii. Dark Shade mainly showing
iii. If not properly use anti Creasing & Wetting agent.
iv. If fabrics not properly open stage in the dyeing nozzle.
v. Rope stage in dyeing.
B. Remedies-
i. Up to mark use anti crease & wetting agent.
ii. Ensure the open stage dyeing & not rope.
35.Elephants Skin:
A. Causes-
i. Mainly coming from compactor machine.
ii. If over compaction.
iii. If taplon/ Glass fiber not proper setting
B. Remedies--
i. Before compactor m/c run then everything checks.
ii. Up to mark feed the over feed.
iii. Taplon/ Glass fiber properly set.
iv. Again compactor under overfeed.

36.Carling:
A. Causes-
i. Mainly that type of problem in dyeing.
ii. If not grading temperature up down.
iii. Mainly CVC & PC fabrics, Polyester fabrics that happen.
B. Remedies-
i. Proper grading system follows.
ii. Again dyeing load & grading maintain
iii. High temperature Finish
iv. Minimum overfeed finishing time.
37.Running Shade/ Meter to meter Variation:
A. Causes-
i. Not properly color dosing
ii. Not properly wash
iii. Pretreatment not good
B. Remedies-
i. After Pretreatment check, absorbency check
ii. After treatment need to good
iii. Up to mark use anti crease & wetting agent.
38.GSM Effect from Dyeing:
A. Causes-
i. If yarn quality not good.
ii. More Enzymes.
iii. Long time dyeing
iv. Reprocess
B. Remedies-
i. Hardly try for one time dyeing
ii. About reprocess
iii. Enzyme up to mark
39. Rubbing Problem:
A. Causes-
i. Dyes not good
ii. Yarn not good
iii. After dyeing not good wash
iv. Enzyme dust in the fabrics

B. Remedies-
i. Good band dyes use
ii. Quality yarn use
iii. Good after treatment
iv. Hydrophilic softener use
40.Body to Rib Not Match:
A. Causes-
i. Yarn lot not same
ii. Yarn count not same
iii. Dyeing Ratio not accurate
iv. If rib separate one nozzle in dyeing
B. Remedies-
i. Must be Yarn lot & Count same
ii. Every nozzle fabrics ratio same
iii. Separate dyeing & Match body
41.Entanglements –
A. Causes-
i. Liquor Ratio More
ii. More Fabrics Loaded
iii. Unbalances Fabrics Loaded
iv. Nozzle to Nozzle Real speed Difference
v. Nozzle Gap & With knots use
vi. More Foam
B. Remedies-
i. Liquor Ratio As required
ii. Up to mark fabrics Loaded with balances Every nozzle
iii. Nozzle gap as fabrics GSM wise
iv. Roll to roll Joint with sewing
v. Anti-foam use

42. Stenter M/c Speed-
A. Causes-
i. Deffand of Fabrics Types
ii. Color Shade %
iii. Shade Adjustment
iv. Moisture Control
v. Filter Not proper Clean
vi. Exhaust need to be adjust
vii. More Overfeed
B. Remedies-
i. Fabrics Type & Color wise Speed adjust
ii. Required wise Moisture adjust
iii. Properly filter Clean
iv. Fabrics Squeezer up to Mark

Quality Reports
1. Quality Policy:
A. Inspection-( Standard )
i. Grad –A (100% OK fabrics) (Points up to 40)
ii. Grad-B (80% OK Fabrics)(40 to 60 Points)
iii. Grad-C (Return to production)
iv. Grad-R (Reject)(60 up points)
B. Return-(For Re-process)
i. Width variation
ii. GSM Low
iii. GSM High
iv. Elephants Scan/ Crumple mark
v. Crease Mark
vi. Color Spot
vii. Hairiness
viii. Running shade
C. Reject-
i. Barriness/ Patta/ Yarn Variation
ii. Needle drop / Wrong Slitting
iii. Thick & Thin
iv. Lycra out
D. GSM Check
i. Near of Stitch
ii. Within one meter
iii. GSM average Required
iv. GSM less than 5 to 7% in fabrics stages
E. Shade Check
i. Near of Stitch
ii. Within one meter
iii. Running shade check
v. Tolerance’s Group A & B
vi. Group wise Cutting to Packing separate
vii. Shade Compare with Spectrophotometer/ grey Scales

Sample Make & Submit
2. Sample Policy:
A. Knitting
i. Proper Count use
ii. Proper Stitch Length
iii. Dia & Gauge Select
B. Dyeing
i. Branded Dyes & Chemical use
ii. Proper wash
iii. Enzyme
iv. Good Hand Feel
v. Fastness
vi. Rubbing
vii. Light Fastness
viii. pH Control
C. Finishing
i. Shrinkage Control
ii. Spirality Control
iii. GSM Control
iv. Bowing /Angle
D. Quality Check
i. Wash Fastness
ii. Shrinkage & Spirality
iii. GSM
iv. Hairiness
v. pH Check
vi. Buyer Requirement
E. Cutting
i. Pattern Adjust against of Shrinkage
ii. Before cutting need steam iron
iii. After Sewing need tumble than steam iron

F. Tasting
i. Test of Garments Stage
ii. Again Lab test before delivery to Customer
iii. Keep Every Test Report
G. Submit
i. Cross check & Conform Everything ok
ii. Two picas Sample Keep in store for References
Note: After sample submit If any problem fully take Responsibility Sample
department because should be everything Re-Check before submit If Result ok
then Send to Buyer, Otherwise correction in department because Tasting Cost is
so much High also time bindings from Customer.
Suggestions:
1. Proper follow-up for every instruction given
2. Database development for all articles in order to avoid batch to batch
setting change
3. Proper information should be in the order sheet/ Planning sheet (Yarn
Count, knitting m/c Dia, Gauge, Stitch Length & Required width, GSM)
4. Before start knitting production must be conform from fabrics finishing
department width & GSM/ Make sample
5. Proper count use according to the Finish fabric requirement
6. All Pique Fabrics should be knitting m/c Dia 30” & Gauge 24 instant of 34”
7. Make availability of all the required spares
8. Need Proper training operators & Workers
9. Fabrics Quality Check need to policy change
10.Dyeing Batch Card/Information Card should be fulfil every requirement
11.Rejection Percentage more than 5% Re-check by senior person
Thanks

Problems analyes & corrective action

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