STANDARD CORRECTIVE ACTION PLAN FOR COMMON TOP DEFECTS

Defects Responsible
Image of Defects Root Cause Analysis Solution
Name Personnel
1. mwVK cØwZ‡Z myBs †gwk‡bi wiper 1.cÖwZwU myBs †gwk‡b wiper
e¨envi bv Kivi Rb¨| e¨envi Ki‡Z n‡e |
1. Sewing machine wiper not used 1. Need to use sewing
properly. machine wiper.
[Link]‡iUi Ges myBs ‡njcvi Zvi wbR wbR 2. Acv‡iUi Ges †njcvi‡`i
Acv‡ik‡b G·Uªv myZv bv †K‡U †`Iqvi Rb¨| G·Uªv myZv KvUvi Rb¨ AbycªvwbZ 1. myBs Acv‡iUi
[Link] 2. Operator and helper do not cut Ki‡Z n‡e| 2. myBs ‡njcvi
Thread their extra thread their own 2. Need to inspire to cut 3.‡KvqvwjwU
operation. extra thread in their own
operation.
 1. ‡dweª‡Ki aib Abyhvqx myBs †_ªW Ges wb‡Wj ১. ‡dweª‡Ki aib Abyhvqx mwVK myPu
wbev©Pb bv Kiv n‡j| (Needle) Ges myBs †_ªW e¨envi
[Link] don’t used proper needle and Ki‡Z n‡e|
Sewing thread according to the 1. Need to use proper
fabrication. needle and sewing thread
2. myBs †gwk‡bi jyc di‡gkb fv‡jvfv‡e bv according to fabric.
n‡j| 2. myBs †gwk‡b fv‡jv cªKv‡ii
1.‡UK‡bwkqvb
[Link] Stich 2. If proper loop formation not †ivUvwi ûK Ges jycvi e¨envi
2.‡gKvwbK
happen during the sewing. Ki‡Z n‡e|
3.‡KvqvwjwU
3. ÎæwUc~b© wb‡Wj e¨envi Kiv n‡j| 2. Need to use good
3. If defective needle have been Routery hook and looper
used. in the sewing machine.
3. †Kvb ÎæwUc~b© wb‡Wj e¨envi
Kiv hv‡e bv|
3. Should not use
defective needle.
[Link] G¨vjvÝ fv‡jvfv‡e
[Link]` mwVKfv‡e myBs G¨vjvÝ †gBb‡UBb bv †gBb‡UBb Ki‡Z n‡e|
Kiv nq| 1. Sewing allowance
1. If sewing allowance not should maintain properly.
maintain properly. 2. c¨vUv©‡bi gv©wKs fv‡jvfv‡e [Link] wWcv©U‡g›U
2. c¨vUv©b gvwK©s hw` fv‡jv bv Kiv nq| †gBb‡UBb| 2. myBs †njcvi
[Link] 2. If do not maintain pattern 2. Pattern marking should 3. myBs Acv‡iUi
marking properly. do properly. 4.‡KvqvwjwU
3. †dweª‡Ki KvU †c‡bj hw` wVKfv‡e bv aiv 3. †dweª‡Ki KvU †c‡bj mgvbfv‡e
nq| ai‡Z n‡e|
3. If fabric cut panel is matched 3. Fabric cut should
properly. handle proper way.
 1. myBs †gwkb mgy‡ni †_ªW †Ubkb
[Link] †gwk‡b †_ªW †Ubkb hw` †ewk nq| †PK Ki‡Z n‡e Ges Acv‡ikb
1. If excessive thread tension on Abyhvqx Zv GWhv÷ Ki‡Z n‡e|
sewing machine. 1. Sewing machine thread
2. wb‡W‡ji wd«Kkbvj wn‡Ui Kvi‡b †_ªW †eªwKs needs to be checked and set
nIqv| according the operation.
2. Needle frictional heat during the
sewing. 2. DbœZgv‡bi myBs †_ªW e¨envi 1.‡gKvwbK
[Link] 3. myBs ‡_ª‡Wi †÷ªš’ Kg nIqvi Rb¨| Ki‡Z n‡e| 2.‡UK‡bwkqvb
Stich 3. Poor Quality sewing thread used. 2. Need to used good 3.‡KvqvwjwU
quality thread.
3.‡dweª‡Ki aib Abyhvqx mwVK myPu
(Needle) Ges myBs †_ªW e¨envi
Ki‡Z n‡e|
3. Need to use proper
needle and sewing thread
according to fabric
1. hw` mwVKfv‡e myBs G¨vjvÝ †gBb‡UBb bv 1.A`ÿ myBs Acv‡iUi‡`i
Kiv nq| cÖwkÿ‡bi e¨e¯’v Ki‡Z n‡e|
1. If sewing allowance not 1. Required training for
maintain properly. unskilled sewing operator.
2. myBs Acv‡iUi‡`i †n‡Ûwjs‡qi Kvi‡b | 2. mwVK myBs MvBW e¨envi Ki‡Z
2. Due to poor handling of sewing n‡e|
1. myBs Acv‡iUi
operator. 2. Need to use proper
2.‡gKvwbK
[Link] 3. Acv‡ik‡bi aib Abyhvqx MvBW e¨envi bv sewing guide.
3.‡UK‡bwkqvb
Kiv n‡j| wKsev MvBWwU mwVKfv‡e e¨envi bv
4.‡KvqvwjwU
Kiv n‡j|
3. Proper sewing machine guide not
used according to operation or
existing guide mistake.
 1. KvU †c‡b‡ji †gRvi‡g‡›U mgm¨v n‡j| 1. KvU †c‡b‡ji KvU gvK© ‡d‡jv
1. Cut panel measurement up/down Ki‡Z n‡e|
cutting department. 1. 100% cut mark follow.
2. myBs Acv‡i‡Ui ‡n‡Ûwjs‡qi Kvi‡b| 2.A`ÿ myBs Acv‡iUi‡`i 1. KvwUs wWcv©‡g›U
[Link] 2. Sewing operator method problem. cÖwkÿ‡bi e¨e¯’v Ki‡Z n‡e| 2. myBs ‡UK‡bwkqvb
2. Required training for 3. KvwUs †KvqvwjwU
unskilled sewing operator.

[Link] mxg MvBW e¨envi bv Kivi d‡j| 1. Acv‡ikb Abyhvqx mwVK mxg
1. If proper sewing guide not used. MvBW e¨envi Ki‡Z n‡e|
2. KvU †c‡bj †gRvi‡g‡›Ui †_‡K eo n‡j| 1. Have to use proper
2. Cut panel measurement bigger sewing guide according to
than required measurement. the operation.
[Link] †dvìvi e¨envi Kiv bv n‡j| 2. KvU †c‡b‡ji †gRvi‡g›U wVK
1.‡gKvwbK
[Link] 3. Do not use actual folder. _vK‡Z n‡e|
2.‡UK‡bwkqvb
Edges 2. Cut measurement should
3.‡KvqvwjwU
be okay.
[Link] gv‡ci †dvìvi e¨envi
Ki‡Z n‡e|
3. Need to use actual folder
according to cut panel
measurement.
 1. hw` mwVKfv‡e myBs G¨vjvÝ †gBb‡UBb bv [Link] G¨vjvÝ fv‡jvfv‡e
Kiv nq| †gBb‡UBb Ki‡Z n‡e|
1. Sewing allowance not maintained 1. Sewing allowance
properly. should maintain properly.
2. ‡dweª‡Ki mv‡_ myBs †_ª‡Wi Kw¤^‡bkb wVK bv 2. ‡dweª‡Ki mv‡_ myBs †_ª‡Wi
n‡j| Kw¤^‡bkb wVK Ki‡Z n‡e|
2. Incorrect threading. 1.‡UK‡bwkqvb
[Link] 2. Sewing thread have to
3. myBs †gwk‡bi †_ª‡Wi †Ubkb wVK bv _vKvi select according to fabric [Link] Acv‡iUi
Seam
Kvi‡b| type. 3.‡KvqvwjwU
3. Tension of sewing thread not right.

[Link]` wb‡W‡ji wUc c‡q›U †fvZv n‡q hvq | 1. wb‡W‡ji mv©c‡bm †PK Ki‡Z
1. If needle tip point is less n‡e Ges †fvZvu wb‡Wj cwieZ©b
sharpness. Ki‡Z n‡e|
2. hw` †Kvb fzj †mjvB †Lvjv nq| 1. Need to check needle
[Link] any worng stitch being open. sharpness and have change
3. myBs Acv‡iU‡ii Agb‡hvMxZvi Kvi‡b| defective needle.
1.‡KvqvwjwU
[Link] 3. Sewing operator unconsciousness. [Link] Acv‡iUi‡`i Kv‡R AviI
[Link] Acv‡iUi
Mark g‡bv‡hvMx n‡Z n‡e| hv‡Z ‡Kvb
3.‡KvqvwjwU
fzj †mjvB bv nq|
2. Sewing operator has to
be more attentive in their
work.
 1. G·Uªv myZv KvUvi mgq †njcvi ev 1. G·Uªv myZv KvUvi mgq †njcvi
Acv‡iU‡ii AmveavbZvi Kvi‡b ‡dweªK †W‡gR ev Acv‡iUi‡`i AviI g‡bv‡hvMx
nq| n‡Z n‡e|
2. Unconsciousness of sewing 1. Have to be more
operator and helper when she/he attentive when removing
cutting extra thread. extra thread. [Link] Acv‡iUi
[Link] [Link]‡W‡ji gv_v †fvuZv ev fv½v n‡j| 2. ‡fvuZv ev fv½v wb‡Wj cwieZ©b 2. ‡njcvi
Damage 2. If needle tip point is sharpness Ki‡Z n‡e| 3.‡KvqvwjwU
less. 2. Defective needle have to
change immediately.

[Link]` R¨v‡K‡Ui d«›U cv©‡Ui mv‡_ †m›Uvi d«›U 1. R¨v‡K‡Ui d«›U cv©‡Ui mv‡_
wRcv‡ii GWhv÷‡g›U wVK bv _v‡K| †m›Uvi d«›U wRcv‡ii GWhv÷‡g›U
[Link] 1. If zipper not adjust properly with wVK _vK‡Z n‡e|
Front the front of the jacket. 1. Center front zipper
Zipper [Link]‡ii †jš’ hw` †c‡b‡ji †_‡K eo nq| should be adjusting 1.‡UK‡bwkqvb
Pointy 2. Zipper length bigger than front properly. 2.‡KvqvwjwU
part panel. 2. wRcv‡ii †jš’ wVK _vK‡Z n‡e|
2. Zipper length should be
okay.
 [Link] Kivi mgq myZv wQ‡o †M‡j| 1. fv‡jv gv‡bi myZv e¨envi Ki‡Z
1. Thread breaking during the n‡e|
stitiching. 1. Have to use good quality
[Link] †K‡mi myZv †kl n‡q †M‡j cybivq hw` thread.
GKB RvqMv ‡_‡K ïiæ †mjvB Kiv nq| [Link] †K‡mi myZv †kl n‡q
2. Thread ending in the bobbin case. hvIqvi Av‡M cybivq myZv evwÛs
3. Acv‡iUi ev †njcvi G·Uªv myZv KvUvi mgq Ki‡Z n‡e|
[Link] Acv‡iUi
[Link] ‡mjvB wQ‡o †d‡j| 2. Thread has to rebinding 2. ‡njcvi
Stitch 3. Stitching cut during the thread before ending sewing
3.‡KvqvwjwU
trimming. thread in the bobbin.
[Link]‡iUi ev †njcvi‡`i myZv
KvUvi mgq AviI g‡bv‡hvMx n‡Z
n‡e|
3. Have to be more
conscious about thread
trimming.
[Link] Kivi mgq hw` myBs‡qi wbw`©ó [Link]`©ó GjvBb‡g‡›U †mjvB Ki‡Z
GjvBb‡g‡›U bv †mjvB Kiv nq| n‡e|
1. Stitching alignment not follow 1. Have to stitch over the
properly. actual alignment. [Link] Acv‡iUi
[Link] [Link]‡iU‡ii Ag‡bv‡hvMx nIqvi Kvi‡b| 2. Acv‡iU‡`i AviI g‡bv‡hvMx 2. ‡njcvi
Stitch 2. Unconsciousness of the sewing n‡Z n‡e| 3.‡KvqvwjwU
operator. 2. Have to be more
attentive during stitching.
 1.‡¯œc evUb †gwk‡bi ‡cÖmvi wVK bv n‡j| 1.‡¯œc evUb †gwk‡bi ‡cÖmvi
1. Snap Button Machine adjustment †evZv‡gi aiY Ges ‡dweª‡Ki aib
not okay. Abyqvqx wVK Ki‡Z n‡e|
1. Snap button machine 1.‡UK‡bwkqvb
14. Button pressure need to be 2.‡gKvwbK
Camp out adjusting with fabric and 3.‡KvqvwjwU
button type.

1. c¨vUv©‡bi gv©wKs wVK g‡Zv bv nIqv Kvi‡b| 1. ‡njcvi‡`i gv©wKs wVK g‡Zv
1. Pattern marking not followed Ki‡Z n‡e|
properly. 1. Mark has to follow
[Link]‡iU‡ii †n‡Ûwjs wVK fv‡e bv n‡j| properly.
1.‡njcvi
[Link]- 2. Handling problem of the sewing 2. Acv‡iUi‡`i c‡q›U wgwj‡q
[Link]‡iUi
Low operator. KvR †mjvB Ki‡Z n‡e|
3.‡UK‡bwkqvb
2. Point have to adjust
according marking

1. evi‡UK ‡cøBm‡g›U wVK bv nIqvi Kvi‡b| 1. evi‡UK ‡cøBm‡g›U wVK n‡Z

1. If bar-tack placement is not okay. n‡e|
2. Bar-tack placement
should be proper.
[Link] Acv‡iUi
Missing
 [Link] hw` Lye UvBU K‡i GWhv÷ Kiv nq| [Link] GWhv÷ fv‡jvfv‡e Ki‡Z
1. If zipper adjustment is too much n‡e|
tight. 1. Zipper adjustment should
[Link] gvK© Ges ewW KvU gvK© hw` wVK g‡Zv be properly.
bv nq| [Link] gvK© Ges ewW gv©K wVK
[Link]‡iUi
2. Zipper mark and body cut mark is g‡Zv Ki‡Z n‡e|
18. Zipper 2.‡njcvi
not adjusted properly. 2. Zipper mark and body
wavy. [Link]‡ii †gRvi‡g›U hw` ewWi †gRvi‡g‡›Ui
3.‡UK‡bwkqvb
mark should to be matched.
4.‡KvqvwjwU
mv‡_ wgj bv nq| [Link]‡ii †gRvi‡g›U Ges ewWi
3. Zipper measurement and body †gRvi‡g›U wVK n‡Z n‡e|
length measurement not adjust. 3. Zipper measurement and
body measurement should
be proper.
1. KvwUs Kivi mgq †kW IqvBR Avjv`v KvwUs 1.‡kW IqvBR Avjv`v Avjv`v
bv Kivi Rb¨| KvwUs Ki‡Z n‡e|
1. Cutting not according to shade 1. Fabric should be cut
wise. shade wise.
2.‡dweªK †jqvi Kivi mgq †kW bv †PK Kivi 2.‡dweªK †jqvi Kivi mgq †kW
Kvi‡b| Ki‡Z n‡e|
2. Cutting quality did not check 2. Fabric shade have to [Link] †cÖvWvKkb
[Link] [Link] †KvqvwjwU
shade during fabric spreading. check during fabric
[Link]‡q Bmy¨-Bbcy‡U wVK gZ †PK bv Kivi spreading
Kvi‡b| 3. Bmy¨-Bbcy‡U wVK gZ †PK
3. Issue – Input not checked in the Ki‡Z n‡e|
sewing line by Quality. 3. Issue –Input have to
check in the sewing floor.
 1.‡gwkb wVK gZ cwi¯‹vi bv Kivi d‡j| 1. cÖwZw`b †gwkb cwi¯‹vi Ki‡Z
1. Sewing machine not cleans n‡e|
properly. 1. Machine need to clean
[Link]©‡g›Um †døv‡i †d‡j ivL‡j| every day.
2. Garments kept on floor and dusty 2. Mv©‡g›Um †døv‡i †d‡j ivLv hv‡e
area. bv|
3. †gwk‡bi I‡qj wj‡KR n‡j| 2. Garments must not keep 1. mKj Acv‡iUi ,
3. Sewing machine oil leakage. on the floor. mycvifvBRvi, jvBb
4. †dweª‡Ki †Kvb cÖKvi ¯úU _vK‡j| 3. †h mKj †gwk‡b I‡qj wj‡KR
[Link] Pxd,‡gKvwbK, ¯^ ¯^
4. Oil leakage on the machine. K‡i Zv cwie©Zb Ki‡Z n‡e|
†døv‡ii GBP Avi
[Link] leaked machine need
Ges GWwgb
to changed.
4. jvBU Kvjvi Mv©‡g›Um Drcv`‡bi
mgq nvZ †gvRv e¨envi Ki‡Z
n‡e|
4. Hand glove need to use
during light color garments
production.