Reduce Defects in Garment Sewing Through Quality Control

Innovations

A thesis submitted by

Basharat Hussain (21-NTU-TE-0107)

Ali Hassan (21-NTU-TE-0102)

In partial fulfillment of the requirement for the degree of

Bachelor of Science

in

Textile Engineering

School of Engineering and Technology

NATIONAL TEXTILE UNIVERSITY, FAISALABAD

November 2024

i
 DEDICATION

This humble effort is dedicated to my

Parents,

Teachers

&

Friends

i
 ACKNOWLEDGEMENT

We are grateful to our teachers, our friends and family members whose efforts made us
capable of performing this work. We are also thankful to the staff of National Textile
University Faisalabad for providing us their services whenever we needed. We would like
to express our heartfelt gratitude to our project supervisor, Dr. Shahood Uz Zaman and
co- supervisor Ms. Aqsa Imran for guiding us throughout this project with expertise and
patience. We also extend our appreciation to our institution for providing necessary
resources and facilities which enabled us to complete this project successfully. We are
also thankful to our friends and family members, who supported us throughout this
project, providing encouragement and motivation when needed. Their support helped us
to overcome challenges and stay focused on our goals. This project would not have been
possible without the collective efforts of all those, and we are grateful for their
contributions.

ii
 CERTIFICATE

NATIONAL TEXTILE UNIVERSITY, FAISALABAD

This thesis, written by Mr. Basharat Hussain & Mr. Ali Hassan under the direction of
(Mr. Shahood Uz Zaman) has been presented to and accepted by the Chairman,
Department of Textile Engineering, in fulfillment of the requirement of the degree of
Bachelor of Science in Textile Engineering.

Co-supervisor Industrial Co-supervisor

Supervisor Section Coordinator / Chairman

Department of Textile Engineering

Date:

iii
 TABLE OF CONTENTS

DEDICATION......................................................................................................................i

ACKNOWLEDGEMENT...................................................................................................ii

CERTIFICATE...................................................................................................................iii

TABLE OF CONTENTS....................................................................................................iv

LIST OF NOTATIONS......................................................................................................vi

LIST OF ABBREVIATIONS............................................................................................vii

LIST OF TABLES............................................................................................................viii

LIST OF FIGURES............................................................................................................ix

ABSTRACT.........................................................................................................................x

SUSTAINABLE DEVELOPMENT GOAL.......................................................................xi

Chapter 1..............................................................................................................................1

Introduction..........................................................................................................................1

1. Major Departments in Garment Industry......................................................................1

1.1.1 Marketing department..........................................................................................1

1.1.2 Sampling Department..........................................................................................2
1.1.3 Fabric Store and Fabric Sourcing Department.....................................................2
1.1.4 PPC (Production planning and Control) Department..........................................2
1.1.5 Cutting Department..............................................................................................2
1.1.6 Sewing Department..............................................................................................2
1.1.7 Industrial Engineering Department......................................................................3
1.1.8 Washing Department...........................................................................................3
1.1.9 Finishing Department..........................................................................................3
1.1.10 Quality Control / Quality Assurance department...............................................3
1.1.11 Human Resource and Administration department.............................................3
1.1. Garment Sewing........................................................................................................4

1.2. Defects in sewing......................................................................................................4

1.2.1. Seam Puckering..............................................................................................5

Causes..................................................................................................................................5

iv
Remedies..............................................................................................................................6

1.2.2. Open seam or broken seam............................................................................7

Causes..................................................................................................................................7

Remedies..............................................................................................................................8

1.2.3. Broken Stitch..................................................................................................8

Causes..................................................................................................................................9

Remedies..............................................................................................................................9

1.3.4. Drop stitch/Skipped stitch..............................................................................9

Causes................................................................................................................................10

Remedies............................................................................................................................10

1.3.5. Uncut/ loose thread.......................................................................................10

Causes................................................................................................................................11

Remedies............................................................................................................................11

1.3.6. Distorted knitting.........................................................................................11

Causes................................................................................................................................12

Remedies............................................................................................................................12

1.3.7. Seam slippage...............................................................................................12

Causes................................................................................................................................12

Remedies............................................................................................................................12

1.3.8. Needle threads breakage...............................................................................13

Causes................................................................................................................................13

1.4. Quality Control/Quality Assurance.........................................................................13

1.4.1. Quality Assurance........................................................................................14

1.4.2. Quality Control.............................................................................................14
1.5. Quality Techniques.................................................................................................15

1.5.1. Flow chart.....................................................................................................15

1.5.2. Check sheet..................................................................................................15
1.5.3. Histogram.....................................................................................................16
1.5.4. Scatter plot...................................................................................................16
1.5.5. Control Chart................................................................................................16

v
 1.5.6. Pareto Diagram.............................................................................................17
1.5.7. Cause-and-Effect Diagram...........................................................................17
1.6. Innovations in Quality Control................................................................................17

1.6.1. Advanced Sewing Machines........................................................................18

1.6.2. Defect Detection Sensors.............................................................................19
1.6.3. Automated Thread Tensioner.......................................................................19
1.7. AI tools for quality control innovation ……………………………………………20

1.7.1 Computer vision for defect detection ……………………………………..20

1.7.2 Predictive maintenance with IoT and AI…………………………………..21

1.7.3 Quality control automation with AI……………………………………….21

1.7.4 Poka yoke integration with AI…………………………………………….22

Literature Review…………………………………………23

Research Gap......................................................................................................................27

Specific Objectives.............................................................................................................27

References..........................................................................................................................29

LIST OF NOTATIONS

vi
 LIST OF ABBREVIATIONS

IE = Industrial Engineering
QC = Quality Control
BOM = Bill Of Material
SAM = Standard Allowed Minutes
SMV = Standard Minute Value
TQM = Total Quality Management
SPC = Statistical Process Control

vii
LIST OF TABLES

viii
 LIST OF FIGURES
Figure 1 Different departments in garment industry............................................................4
Figure 2 Seam puckering ....................................................................................................5
Figure 3 Open seam.............................................................................................................8
Figure 4 Broken stitch .........................................................................................................9
Figure 5 Skip stich.............................................................................................................10
Figure 6 Loose thread ........................................................................................................11
Figure 7 Distorted knitting.................................................................................................12
Figure 8 Seam slippage [10]..............................................................................................12
Figure 9 Needle thread breakage........................................................................................13
Figure 10 Use of 7QC tools in process identification........................................................17
Figure 11 Advanced sewing machines...............................................................................18
Figure 12 Automated grading system................................................................................20
Figure 13 Automated thread tensioner...............................................................................21
Figure 14 CAD system.......................................................................................................22

ix
ABSTRACT

x
 SUSTAINABLE DEVELOPMENT GOAL

In this research, SDG 9 has been targeted. The innovations in quality control processes
can reduce the defects in garment sewing.

xi
 Chapter 1
Introduction
Garments refer to items of clothing or textile products worn on the body to cover or adorn
it. They are designed to provide protection, modesty, comfort, and style. Garments can be
made from various materials like fibers, fabric or leathers and can range from simple to
complex designs.

Garments are produced mainly on two bases. The first one is tailoring based and the
second one is industrial based. The making of garments for a particular man, taking his
body measurements is called tailoring based garments production. Making of thousands
pieces of garments for male, female, boys or girls taking standard body measurements
based on a specific design and different sizes is called the industrial based garments
production [1].

1. Major Departments in Garment Industry

There are several departments in garment industries like HR (Human Resources)
department, Marketing department, PPC (Plan Production and Control) department, FID
(Fabric Inspection department), CAD (Computer Aided Design) department, Cutting
department, Sewing department, Washing department, QC (Quality Control) department
Finishing department, Packing department and at the end is dispatching of garment. Every
department has its own functions and responsibilities and is responsible to head of that
department. These departments work together to design, produce and distribute products
[2].

Here is detail of these departments:

1.1.1 Marketing department

The marketing department in a garment industry is responsible for marketing products
made by the factory, finding new customers, and bringing more and more orders for the
company.

A marketing department is headed by the marketing manager and supported marketing

team. They show their latest product development (designs) to the buyer. They are given
responsibility for business development for the company.

1
1.1.2 Sampling Department
Sampling department makes all kind of samples that need to be submitted to the buyer.
Sampling department checks fit of the sample. Sampling department communicates
problems related to orders to the production department.

Sampling department perform activities like, Reading garment spec and understanding
workmanship of the garment ,Help merchants in preparing BOM, Making garment
samples by following complete processes of cutting, sewing, finishing and checking [2].

1.1.3 Fabric Store and Fabric Sourcing Department

The fabric store is handled by Fabric in-charge and the in-charge is assisted by a team of
helpers for loading and unloading fabrics and issuing fabric to cutting department. Fabric
department receives and stores all kind of fabrics. Fabric rolls are kept in the rack or on
wooden pallets.

1.1.4 PPC (Production planning and Control) Department

Production planning department is responsible for planning and scheduling orders. This
department is known as PPC department. They execute production and do follow with all
production processes. Production planning and scheduling of activities are essential to
procure raw material on time, complete production activities on time and able handover
shipment on time.

1.1.5 Cutting Department

This department is responsible for cutting of fabrics and feeding sewing department with
cuttings. Cutting department’s capacity is planned as per daily feeding requirement to the
sewing lines.

Cutting department set up with cutting department head, cutters, spreaders, quality
checkers, and helpers for sorting, ply numbering and bundling. Cutting is done by
manually and also by computerized [3].

1.1.6 Sewing Department

Sewing clothing is the sewing department’s primary responsibility. The sewing floor
uses a variety of line layouts and production systems. Factories operate using either a
group system or an assembly line. This department’s primary responsibilities include line
setting, sewing, marking, ironing, checking stitched items, stitching alterations, and more
[4].

2
1.1.7 Industrial Engineering Department
The department of industrial engineering assists the production department with line
setting, production improvement, and performance measurement. Product analysis,
operation bulletin creation, garment SAM calculation, line layout, and workstation layout
are the main tasks performed by the Industrial Engineering department. They compile
daily production reports and record production data. Additionally, they compute SMV
(Standard Minute Value) and SAM (Standard Allowed Minutes) [5].

1.1.8 Washing Department

Sometimes garments need to be washing after stitching to remove dust, tracing mark and
to give a washed look to the garment. This department washes the garments, cut panels (if
required), wash garment samples as required. Garment washing is also required for
comfort because when garment is unwashed then it will be hard and it can damage the
sling and after washing it will be soft so it body can feel better washed garment.

1.1.9 Finishing Department

Clothing that has been stitched is completed before being placed in a plastic bag. Thread
trimming, clothing inspection, and ironing are the main tasks of a finishing department. In
a factory, the packing and finishing departments operate side by side.

The finishing section is where clothes are folded, tagged, and packed. Activities in the
finishing room may differ depending on the product categories [6].

1.1.10 Quality Control / Quality Assurance department

Department of Quality Assurance and Control Organizations may have different
responsibilities for the quality control department, but the primary tasks are essentially
the same. The following are the activities carried out by the quality control department.
establishing quality assurance, quality standards, and quality SOP.

1.1.11 Human Resource and Administration department

This department is concern about the social issue of the employee. They look after
recruiting and employee welfare. This department maintains employee attendance and
absent records. This department also Handle labor issues, Factory compliance and social
compliance, New employee orientation [7].

There is a flow chart of different departments in garment industry in Figure 1 Different

departments in garment industry . These departments play vital role in any garment
industry.

3
 Merchandizin Quality
Washing
g Control
Department
Departmbent Department

Sampling Sewing Finishing

Department Department Department

Fabric Store & Spreading,

Packing
Fabric Sourcing Cutting
Department Department
Department

Marker
IE Dispatching
Planning
Department Department
Department

Figure 1 Different departments in garment industry

1.1. Garment Sewing
Sewing is the process of fastening or attaching two parts of fabric using stitches made
with a needle and thread. It is one of the basic steps of the apparel manufacturing process.
The sewing section is the most important department of the garment
manufacturing industry. Garment sewing is the major part of textile industry, providing
clothing, accessories and textile products for various applications. Ready-made garment is
totally incomplete without sewing process [8].

1.2. Defects in sewing

An imperfection or abnormality that impairs quality, function or utility. A defect is
associated with a quality characteristic that does not meet certain standards. One are more
defects in a product can make it unacceptable. The modern term for defect is non-
conformity [9].

Defective product is one of the common problems shared by all companies. 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.

There are different types of defects that can occur in garment sewing process due to
different types of reasons such as Skipped stitches, Unbalance stitch, Seam slippage,
Needle thread breakage, Frequent thread, breakage/Brocken stitch, Seam grin, Variable
stitch density, Seam puckering, Bobbin or looped thread breakage, Thread fusing when
sewing machine stops, Uneven Stich, Irregular stitch, Pitch error, Needle Mark,
Wavy/Staggered stitch etc. Now a days Garments defect is one of the most important

4
factors of the apparel manufacturing industry because it creates a negative effect on actual
productivity. f there is no idea of garments defects identification then it will be a tough
job, but if it is known properly then it is an easy task to identify defects [11].

There is detail of sewing defects with their root causes and remedies in detail.

1.2.1. Seam Puckering

Seam puckering refers to the gathering of a seam either just after sewing or after
laundering causing an unacceptable seam appearance.

Here’s shown a seam puckering in [11] [10]Figure 2 Seam puckering [10] which can be
due to thread tension, uneven stretching of fabric or due to stitch tension [11].

Figure 2 Seam puckering [10]

Causes
i. Uneven stretching on to plies of fabric during sewing. Uneven stretching
occurs due to following reasons:

Uneven Fabric Movement: When sewing, the machine feeds both layers of fabric under
the needle. If one layer moves faster than the other, it stretches more, creating uneven
tension between the layers.

Stitch Tension: The sewing machine’s needle and thread form stitches that hold the
layers together. If one layer has stretched more than the other, the stitches end up pulling
the fabric back to fit the seam. This pulling gathers the fabric slightly, creating tiny
wrinkles, or “puckers,” along the seam.

Presser Foot Pressure: The presser foot, which holds the fabric down, can sometimes
press too hard or not hard enough, causing one layer to slip or stretch as it moves through
the machine.

5
Thread Tension: If the machine’s thread tension is too tight, it pulls too hard on the
fabric as stitches are formed, stretching it unevenly.

Different Fabric Properties: Some fabrics, especially those that are stretchy or thin, are
more prone to puckering if they’re not handled carefully during sewing.

Remedies
To prevent this, Feed dog, eyelets and thread guides should be checked periodically for
damages.

Use proper tension settings, adjust the presser foot pressure for your fabric type, and
avoid pulling or stretching the fabric as you sew. A walking foot attachment, which
moves all fabric layers evenly, can also help prevent seam puckering [12].

ii. Improper thread tension.

Seam puckering often happens when the thread tension isn’t set correctly on the sewing
machine. Thread tension refers to how tightly or loosely the machine holds the thread as it
makes each stitch. When the tension isn’t balanced, it can lead to puckering along the
seam.

Here’s detail of that how improper thread tension causes seam puckering:

Too Tight Tension: When the thread tension is too tight, the thread pulls too hard on the
fabric layers. As a result, it stretches and gathers the fabric along the seam. This
stretching causes the fabric to wrinkle or pucker, as it doesn’t lie flat under the tight
stitches.

Too Loose Tension: If the thread tension is too loose, the stitches become loose and
uneven, which can also lead to puckering. Loose stitches may not hold the fabric layers
together firmly, allowing one layer to move or shift slightly. This movement causes the
fabric to bunch up and creates puckers along the seam.

Remedies

To avoid puckering caused by thread tension, it’s essential to:

Adjust the tension setting based on the type of fabric, test the tension on a fabric scrap
before sewing the final piece, and aim for balanced stitches that don’t pull or look too
loose [13].

iii. Incorrect needle size

6
Using an incorrect needle size during sewing can cause seam puckering by disrupting
how the needle moves through the fabric. The needle needs to be the right size for the
fabric thickness and type; otherwise, it won’t create smooth, even stitches. If the needle is
too large for delicate fabric, it makes bigger holes and can drag or pull the material,
causing small gathers or puckers along the seam line.

On the other hand, if the needle is too small for thicker fabrics, it struggles to penetrate
smoothly, creating uneven stitches and sometimes causing the thread to pull or break.
This uneven stitch tension leads to puckering, as the fabric isn’t held securely or evenly.

Remedies

Using the correct needle size ensures smooth stitching, as it lets the needle move cleanly
through the fabric without stretching, tearing, or causing unnecessary tension, which
helps prevent puckering [14].

1.2.2. Open seam or broken seam

Portion of the garment that has not been covered by sewing thread. A seam that has come
undone or separated, exposing the raw edges of the fabric.

The [11] [10]Figure 3 Open seam [10]s howing a defect of sewing which is called open
seam/broken seam. This is offetnly happen due to poor stitching quality, inadequate
thread tension etc [15].

Figure 3 Open seam [10]

Causes
i. Improper handling of the parts of garments.

Broken seams from improper handling of clothing components during sewing can weaken
the item and increase its likelihood of tearing. Collars and sleeves, for example, may get
misaligned or strained if not handled carefully. The thread may break as a result of the
increased strain this places on the stitches.

7
Furthermore, improper alignment of the fabric pieces may result in a weak seam, which
raises the possibility of ripping. It’s crucial to handle each component delicately and
stitch them in the proper positions to avoid this. This results in more robust, uniform, and
long-lasting seams.

ii. Insufficient seam allowance

Insufficient seam allowance can lead to broken seams because there isn’t enough fabric
along the edges to hold the stitches securely. Seam allowance is the extra fabric added
beyond the seam line to give the stitches something to hold onto.

If this allowance is too narrow, the stitches are closer to the fabric’s edge, making them
more likely to pull out or fray when the garment is worn or washed. With a small seam
allowance, there’s also less room to repair or reinforce the seam if it starts to come apart.
This weakens the seam, making it more likely to break under pressure.

By using a proper seam allowance, there’s enough fabric to create a strong, durable seam
that holds up well over time [16].

iii. Improper setting needle and looper or hook

Improper setting and timing between the needle and the looper or hook can cause broken
seams in garments because the stitching process doesn’t happen smoothly.

In a sewing machine, the needle and looper (or hook) need to work in perfect timing to
form each stitch correctly. If they’re out of sync, the needle might miss the looper or
hook, causing skipped stitches or weak loops that don’t hold the fabric together well. This
weak stitching can unravel or break easily, especially when the garment is stretched or
under pressure. Properly timed movement between the needle and looper ensures each
stitch is formed securely, creating a strong seam that doesn’t come apart.

Remedies
In order to prevent these causes follow the following instructions as clear markings for
stitch line, proper setting and timing between needle and looper or hook, Tension should
be quantifiable [16].

1.2.3. Broken Stitch

Non-continuous sewing thread. A broken stitch refers to a disrupted or incomplete stitch
formation, resulting in a weakened or failed seam [17].

8
Here is a [11] [10]Figure 4 Broken stitch [10] of a knitted fabric. Broken stitch can be
due to needle damage or improper tension settings.

Figure 4 Broken stitch [10]

Causes
It appears due to improper trimming or machine usage

Improper trimming can lead to broken stitches in garments because when excess thread or
fabric edges aren’t trimmed neatly, they get caught in the sewing machine or snagged
during wear. This added tension and friction on the stitches weakens them, causing them
to snap or break.

Additionally, if the fabric isn’t trimmed smoothly, uneven edges can tug on the stitches,
creating extra strain.

Over time, this causes the stitching to unravel, which not only affects the garment’s
appearance but also reduces its durability. Proper trimming ensures a cleaner finish and
helps maintain the strength and longevity of the stitches.

Remedies
To prevent this needle plate, presser foot and feed dog should be checked periodically for
damages, tension and threading should not be fiddled with much and proper trimming.

1.3.4. Drop stitch/Skipped stitch

Irregular stitching along the seam. It refers a defect where one or more stitches are
missing in a seam or a row of stitching [18]. More information about this is explained
with the help of [11] [10]Figure 5 Skip stich [10].

9
 Figure 5 Skip stich [10]
Causes
It appears due to improper handling of cut pieces or machine usage

Improper handling of cut pieces or incorrect machine usage can cause skipped stitches in
garments.

When cut fabric pieces are handled roughly, they can stretch or become misaligned,
which disrupts the machine’s needle as it tries to sew evenly. This makes it hard for the
needle to catch the thread correctly, resulting in skipped stitches. Similarly, if the sewing
machine isn’t used properly such as using the wrong needle, incorrect thread tension, or
an improper sewing speed the stitches won’t form as they should.

This can lead to gaps in the stitching, affecting the garment’s quality and durability.
Proper handling of fabric and correct machine usage help ensure consistent, strong
stitching.

Remedies
To prevent from these causes place needle properly, needle size & thread size must be
adjusted. The pressure of pressure foot must be adjusted accurately also. [18]

1.3.5. Uncut/ loose thread

Extra threads or loose threads on seam line. A thread that has not been trimmed or
secured, protruding from the garment [19].

Here is the more understanding is also shown by [20] [20]Figure 6 Loose thread [20].

10
 Figure 6 Loose thread [20]
Causes
It appears due to improper trimming or finishing

Improper trimming or finishing can lead to loose threads in garments because when the
edges of the fabric or threads aren’t cut or secured properly, they can fray or unravel.

If excess threads are left untrimmed, they can easily become loose and visible, creating an
untidy appearance. Additionally, if the finishing techniques, like serging or binding, are
not done correctly, they might not secure the fabric edges properly. This can allow
threads to pull free, especially during washing or wearing. To prevent loose threads, it’s
important to trim and finish the edges neatly, ensuring that everything is secured tightly.

Remedies
To prevent this cause thread trimmer should be used, operator training should be
performed, and garments finishing should be checked properly [19].

1.3.6. Distorted knitting

It refers to irregularities or evenness in knitted fabrics, affecting the fabric’s texture,
appearance and performance. It is also shown in [21] [21]Figure 7 Distorted knitting
[21].

11
 Figure 7 Distorted knitting [21]
Causes
These defects can be identified by looking at the surface area; they usually appear as
irregular on the fabric.

Remedies
To prevent from this cause, apply better inspection of fabric and cut pieces, ensure that
fabric and cut pieces that are not up to standard are not put into line and production is
wasted.

1.3.7. Seam slippage

It is the movement or shifting of fabric along a seam, resulting in a compromised or failed
seam.

[11] [10]Figure 8 Seam slippage [10] is showing defect in denim jeans. This can be
parallel, perpendicular or angular slippage.

Figure 8 Seam slippage [10]

Causes
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.

Remedies
To prevent from this cause French seam type can be tried or Seam width can be increased
[22].

12
 1.3.8. Needle threads breakage
It is the sudden snapping or breaking of the thread while sewing, resulting in interrupted
stitching and potential fabric damage.

Needle thread breakage is a common issue in sewing that can impact efficiency and
product quality. [11] [10]Figure 9 Needle thread breakage [10] showing this defect from
where we can see that how this defect is common and it can impact the efficiency.

Figure 9 Needle thread breakage [10]

Causes
i. Thread gets trapped at the thread guide

Thread can get trapped at the thread guide, causing needle thread breakage in garments
because when the thread is not feeding smoothly, it can create extra tension on the
needle. The thread guide is designed to help the thread move easily to the needle, but if
the thread is tangled or incorrectly threaded, it can get stuck.

When this happens, the needle has to work harder to pull the thread through, which can
lead to the thread snapping. Additionally, if the thread guide is damaged or dirty, it may
not guide the thread properly, further increasing the risk of breakage. To avoid this
problem, it’s important to ensure that the thread is threaded correctly and that the thread
guide is clean and in good condition.

ii. Damages in needle guard, throat plate.

Remedies
In order to prevent these type of causes use a foam pad or a similar device to prevent the
package from tilting, ensure that the re-threading is done correctly and also replace the
needle with one of better quality [14].

1.4. Quality Control/Quality Assurance

Quality Assurance (QA) and Quality Control (QC) are two important steps in making
sure products meet high standards.

13
 1.4.1. Quality Assurance
It focuses on the process of making a product. It ensures that every step, from designing
to production and beyond, meets quality standards. This helps prevent mistakes from
happening in the first place.

Quality assurance in garment manufacturing allows you to minimize defects, improve

productivity and efficiency, reduce costs and maximize customer satisfaction. Quality
assurance in the textile industry is crucial for ensuring that the fabrics and garments
produced are of high quality, safe, and meet customer expectations. This process involves
a series of steps that manufacturers follow to maintain quality throughout production. The
aim is to minimize defects and ensure that products meet the required standards before
they reach consumers [23].

The first step in quality assurance is the inspection of raw materials. Textiles are made
from various materials, such as cotton, polyester, wool, and silk. Each of these materials
has its own set of quality standards. Before production begins, companies check the raw
materials for defects, such as inconsistencies in color, texture, and strength. This initial
inspection helps prevent issues later in the production process.

Once the raw materials are approved, the next stage is to monitor the production process.
This involves checking the machinery, equipment, and the techniques used by workers.
Quality assurance teams often use specific guidelines and standard operating procedures
to ensure that the manufacturing process is consistent. Regular checks are conducted to
make sure that machines are functioning properly and that workers are following the right
techniques. If any issues arise, such as a machine malfunction or a worker not following
procedures, immediate action can be taken to correct the problem [24].

1.4.2. Quality Control

Quality is a number of product features that fulfills the customer requirements. Quality
control focuses on the final product. It is also defined by two things consumers and
producers. Producers determine requirements while consumers determine needs. After
manufacturing is complete, QC checks the product's quality and sorts it into two
categories: acceptable or unacceptable. This ensures the product meets expectations and is
ready for customers.

Quality control is performed at various stages of the garment production process. It is

usually done by inspectors who check for defects and other issues at stipulated
checkpoints before the garments go out for delivery. Inspectors look for things like

14
cutting mistakes, color variations, stitching mistakes, holes in the fabric, faulty zippers,
correct labeling, and much more [25].

1.5. Quality Techniques

There are different quality techniques that are used to reduce defects in different
industries like SPC (Statistical Process Control), TQM (Total Quality Management), Six
Sigma, Lean Manufacturing, DMAIC (Define, Measure, Analyze, Inspect, and Control)
PDCA and 7QC tools. 7QC tools are used from the beginning of product development to
production of product. There are different types of tools that are used in quality control
and quality assurance but the selection of a best tool is not a easy task. Quality tools are
not the remedies of every problem and causes of defects but they can be used for the
problem solving processes. There are hundred types of tools in today’s and many
scientists tried their best to differentiate them.

There’s explanation of 7QC tools they are easy to learn and handle. The seven quality
tools were first emphasized by Ishikawa (in the 1960s), who is one of the quality
management gurus [23].

There are seven quality tools which are basic for all other tools are:

1) Flow chart
2) Pareto diagram
3) Check sheet
4) Control chart
5) Histogram
6) Scatter plot
7) Cause-and-effect diagram [26].

1.5.1. Flow chart

It is one of the effective method that is used in quality. It is a drawing of process. It could
be used from start to finish of the process. It uses symbols, arrows, and text to illustrate
the steps involved in a process. The common symbols that are used in flow chat are Oval,
Rectangle, Diamond and arrows etc [27].

1.5.2. Check sheet

It is a tool in which the items that are inspected are noted on a printed form sheet that can
be collected easily. Check sheets are tools for collecting data. They are designed specific
to the type of data to be collected. Check sheets aid in systematic collection of data. Some

15
examples of check sheets are daily maintenance check sheets, attendance records,
production log books, etc.

1.5.3. Histogram
It is method that is used to find variations and it is also used to summarize the data that is
analyzed and then it is represented graphically. Histograms or Frequency Distribution
Diagrams are bar charts showing the distribution pattern of observations grouped in
convenient class intervals and arranged in order of magnitude. Histograms are useful in
studying patterns of distribution and in drawing conclusions about the process based on
the pattern [28].

1.5.4. Scatter plot

It is used to show the relationship of two variables and also used to determine that
whether the relationship is positive or negative. As measurement and collection of data
forms the basis for any analysis, this activity needs to be planned in such a way that the
information collected is both relevant and comprehensive. When solving a problem or
analyzing a situation one needs to know the relationship between two variables. A
relationship may or may not exist between two variables. If a relationship exists, it may
be positive or negative; it may be strong or weak and may be simple or complex [29].

1.5.5. Control Chart

It is used to determine the upper control and lower control limit of the data to determine
the process performance. Control chart or map control is a graphic comparison of data
performance process. There are 5 types of control charts:

X – Chart: a chart that used for an average price, and chart this is the most frequently
used.

R – Chart: used alongside the X - Chart, intended to show the magnitude of the variation
of each subgroup.

P – Chart: used to indicate the value of the defect (percent defective).

Pn – Chart: is used to control the number of defects with sample values fixed size.

C – Chart: used to indicate the number of times the value of the actual defect (not in
percent) per piece or per unit [30].

16
 1.5.6. Pareto Diagram
These are used to classify the problems according to causes and symptoms. This tool is
used in SPC and quality improvement to prioritize projects for improvement, prioritize
the formation of corrective action teams to address issues, identify the products that
receive the most complaints, determine the type of complaints that occur most frequently,
determine the most common reasons for rejections, and for other related purposes. The
80/20 rule is another name for the Pareto principle [31].

1.5.7. Cause-and-Effect Diagram

It is also known as fish-bone diagram because its shape is like a bone of fish. This
diagram was developed in 1950 by a Japanese quality expert. These are used to find the
problems and also determine the causes of these problems. A Cause-and Effect Diagram
is a tool that shows systematic relationship between a result or a symptom or an effect and
its possible causes. It is an effective tool to systematically generate ideas about causes for
problems and to present these in a structured form. This tool was devised by Dr. Koru
Ishikawa and as mentioned earlier is also known as Ishikawa Diagram [30].

Here’s a brief detail in [28]Figure 10 Use of 7QC tools in process identification [28] that
how these tools are used and for what purposes they are best useful.

Figure 10 Use of 7QC tools in process identification [28]

1.6. Innovations in Quality Control

There are many innovative machines and techniques that are used in sewing of
garment but some of these are following:

1. Advanced Sewing Machines

2. Automated Thread Tension
3. Defect Detection Sensors

17
 1.6.1. Advanced Sewing Machines

An advanced sewing machine is a current tool made to increase sewing efficiency, speed,
and ease of use. In contrast to conventional sewing machines, modern models include
several automated functions that make them flexible and easy to operate. They frequently
come with computerized controls that let users choose from a variety of stitch patterns,
change the widths and lengths of the stitches, and even make their own unique designs. In
order to save time and effort, many sewing machines come with touchscreens, USB ports
for importing designs, and automatic threading systems. These characteristics make them
perfect for both who need accuracy and originality in their sewing projects and
professionals working in fields like upholstery, embroidery, and clothing manufacture.
Among the many noteworthy benefits of a sewing machines its capacity to manage
challenging assignments. For instance, these machines have no trouble sewing through
strong materials like leather and denim or through several layers of cloth. Some models
even have monogramming possibilities, embroidery capabilities, and quilting features.
Furthermore, they frequently feature speed control settings that let users sew at a
comfortable pace—a feature that’s especially helpful for complicated work. Their
durability and dependability are additional important advantages. High-quality parts are
used in the construction of sophisticated sewing machines to guarantee long-term
performance and seamless operation. Both novice and expert users might benefit from the
built-in lessons or step-by-step instructions that many of them offer. Even though these
devices can cost more than entry-level ones, their sophisticated features and time-saving
potential make them an excellent investment for anyone hoping to increase production
efficiency or improve their sewing abilities. All things considered, cutting-edge sewing
machines blend functionality and technology to provide unparalleled quality and
simplicity for sewing operations, serving a broad spectrum of customers and applications
[32].

Figure 11 Advanced18
sewing machines [32]
 1.6.2. Defect Detection Sensors
Advanced instruments called defect detection sensors are employed in several industries
to find defects or abnormalities in materials, goods, or procedures. Because they
guarantee that only flawless products are delivered to clients, these sensors are essential
to quality control. The manufacturing, textile, electronics, and packaging sectors all make
extensive use of them. In production lines, defects like as cracks, scratches, misalignment,
color changes, or missing pieces can be found with the aid of defect detection sensors.
Businesses can use these sensors to cut waste, boost productivity, and uphold high
standards of quality. The type of sensor and the flaw it is intended to detect determine
how defect detection sensors operate. The majority of sensors use cutting-edge
technology to identify flaws, such as lasers, infrared, vision systems, or ultrasonic waves.
A vision-based sensor, for instance, combines cameras with software for taking pictures
of a product and comparing them to a reference image. The system marks deviations as
flaws if they occur. A light beam is directed onto a material’s surface using laser sensors;
if the reflected light is broken or dispersed in an irregular pattern, this signifies a defect.
In a similar manner, ultrasonic sensors identify interior flaws in solid objects, such as
cracks or air pockets, using sound waves. Usually incorporated into automated systems,
these sensors provide real-time manufacturing defect identification. Because of their fast
operating speeds, they can ensure continuous inspection without causing the
manufacturing process to slow down. Advanced defect detection systems are quite
effective since they can even automatically categorize and sort defective products. All
things considered, defect detection sensors are critical to raising the caliber of product
finding and fixing defects before products leave the production, cutting expenses, and
guaranteeing customer happiness [33].

1.6.3. Automated Thread Tensioner

Modern sewing machines and textile equipment use a technology called automated thread
tension, which regulates the thread’s tension automatically during stitching as shown in
[35]Figure 12 Automated thread tensioner [35]. The force exerted on the thread as it
passes through the sewing machine is referred to as thread tension. Sustaining the right
thread tension is essential to creating stitches of superior quality. An excessive amount of
tension may break the thread or result in puckering in the fabric. The stitches may seem
uneven or come undone quickly if it is too loose. By doing away with the necessity for
manual adjustments, automated thread tension devices solve these problems and
guarantee reliable outcomes. The system uses sensors to track the thread’s tension and
movement in real time. These sensors pick up any variables and automatically modify the

19
tension according to the sewing speed, thread thickness, and cloth type. For example, the
system adjusts to maintain equal and smooth stitches while sewing heavier materials or
when using ornamental threads. In industrial stitching, when accuracy and speed are
crucial, this function is extremely helpful. There are various benefits to automated thread
tension. It saves time and material expenses by guaranteeing uniform stitch quality,
minimizing thread breakage, and preventing fabric damage. By reducing downtime
brought on by manual adjustments or thread-related problems, it also increases
productivity. Additionally, by eliminating the need for manual tension adjustments, this
technology lowers the learning curve for users, making sewing easier. Both home and
commercial sewing machines frequently employ this approach, especially when making
clothing applications for upholstery and embroidery. Automated thread tension has
become a crucial component of contemporary sewing and textile operations due to its
ability to increase productivity and guarantee faultless outcomes. It makes stitching easier
and consistently produces results of a high caliber [35].

Figure 12 Automated thread tensioner [35]

1.7 AI tools for quality control innovation

Artificial intelligence (AI) is changing manufacturing by enabling previously unheard-of

levels of efficiency, precision, and customisation in product design, production, and
delivery. An overview of the ways artificial intelligence (AI) is affecting the
manufacturing scene is presented in this introduction, along with a discussion of the
technology's importance, prospective uses, and future consequences. Artificial
intelligence (AI) has rapidly evolved from a theoretical idea to a practical instrument that
may simplify processes and resolve difficult problems in a variety of sectors. AI is able to

20
replicate human intelligence and learning. AI is not merely an extra manufacturing tool;
rather, it is a crucial part of the impending Industrial 4.0 revolution. [35]

Below are some AI tools and techniques specifically tailored to reduce defects in the
garment industry.

1. Computer vision for defect detection

2. Predictive maintenance with IoT and AI

3. Quality control automation with AI

4. Poka-yoke integration with AI

1.7.1 Computer vision for defect detection

A state-of-the-art method for automatically identifying fabric and stitching flaws

in clothing manufacture is computer vision for defect detection. This technology
continually and in real-time scans clothing using high-resolution cameras. These
cameras take close-ups of the fabric and stitching, which AI-powered algorithms
then examine. The algorithms are trained to identify specific defects such as
skipped stitches fabric tears uneven seams misalignments and other
inconsistencies. Specialized tools like Google Cloud Vision AI, which employs
sophisticated image processing algorithms to identify irregularities in fabric
patterns and sewing quality, improve the process. Similar to this, Scortex, a tool
made especially for industrial visual quality inspection, guarantees accuracy and
dependability by offering detailed analysis suited to factory settings. As fabric
kinds, patterns, and production techniques change over time, these technologies
can learn and get better. [36]

1.7.2 Predictive maintenance with IoT and AI

In the clothing industry, predictive maintenance using IoT and AI is a proactive

strategy to guarantee optimal equipment performance and avoid machine-related
faults. Machines have sensors placed to track vital characteristics like temperature,
speed, and tension in real time. Artificial intelligence (AI)-powered systems use this
data to forecast possible machine faults before they happen, allowing for the
scheduling of maintenance on time. Important tools in this process include AWS IoT
Analytics, which tracks and predicts machine data, and Uptime AI, which is
developed for industrial processes. Predictive maintenance guarantees continuous

21
production, minimizes errors like loose seams and skipped stitches, and cuts
downtime by addressing possible problems early. For contemporary industrial
processes, this method is a great advantage since it increases productivity, prolongs
the life of equipment, and maintains consistent product quality. [37]

1.7.3 Quality control automation with AI

AI-powered quality control automation improves manufacturing quality assurance

procedures' uniformity and efficiency. AI-powered technologies combine information
from several inspection sites to precisely detect and fix flaws. These automated
technologies enable prompt remedial action by providing instant feedback on quality
faults. This strategy relies heavily on tools like Infinity QS Proficient, which offers
real-time quality control and defect analysis, and ETQ Reliance, which automates
quality inspections and monitors defect trends. These technologies guarantee constant
product quality, drastically cut down on manual labor, and limit the possibility of
faults remaining undetected by simplifying quality control procedures. Better client
satisfaction and more dependable production are the outcomes of this. [38]

1.7.4 Poka-yoke integration with AI

By integrating Poka-Yoke with AI, sophisticated mistake-proofing techniques are

introduced to reduce human error in production processes. AI systems keep an eye on
things in real time and can spot mistakes like misalignments, wrong thread utilization,
and incorrect settings. The system stops production when a problem is detected to
stop more flaws and gives operators detailed information on how to fix the error. By
adjusting to certain manufacturing requirements, custom AI-driven mistake-proofing
technologies improve this process. This proactive strategy guarantees that flaws are
avoided at their origin, greatly lowering the need for post-production checks.
Consequently, it enhances the quality of the final product, optimizes processes, and
lowers production waste and downtime. [39]

22
 Literature Review

During production in sewing Process can be create some faults or defects, that can be
causes low quality of the garments item. Some Faults are recoverable and some cannot
recoverable. Sewing faults can be causes of lower price of Products, which not
economical friendly for the Garments industries. Palaniappan et al studied 10 garment
styles to identify common sewing defects, their causes, and proposes remedial measures
to improve productivity. Some frequent defects include fabric holes, oil stains, and
broken stitches, affecting up to 27.5% of garments. Out of the various Defects occur in
garments, fabric hole and oil stain accounts for 18 to 43% for various styles. It was also
studied preventive measures such as regular machine maintenance, operator training, and
thorough fabric inspections. Addressing these issues can minimize defects, ensuring
higher efficiency and cost-effectiveness in apparel production [37].

Bansal et al studied on identifying and analyzing factors that cause sewing damages and
defects in garments, specifically woven and knitted fabrics. Some factors include fiber
type, yarn structure, fabric construction, sewing thread, and machine parameters.
Common sewing damages such as needle cuts, seam slippage, seam grinning, and
cracking are affected by these variables. The review shows that while woven fabrics have
been mostly studied, there is limited research on knitted fabrics, which are more involved
in sewing damages due to their loop interlacement and elasticity. It was also showed the
importance of understanding and controlling fabric sewability, which refers to how easily
fabric can be sewn without damage. Various fabric properties, such as fiber blend ratios,
yarn twist, and fabric structure, along with machine settings like needle size and stitch
density, play a important role in determining seam quality. The research suggests that
reducing sewing damages requires a wide approach involving careful selection of fabric
materials, sewing threads, and machine settings. The main goal is to provide awareness to
garment manufacturers and researchers to minimize defects and improve seam quality for
better garment production outcomes [19].

In present the ready-made Garments is one of the parts of garments sector. On the other
hand, the ready-made garment is totally incomplete without sewing process. But it is true
that, sometimes we do not get the expected result in this section. It is because of lack of
Proper skill, machine disturbance and improper machine adjustment. Islam et al studied
the main defects include seam puckering, broken seams, broken stitches, skipped stitches,

23
loose threads, distorted knitting, seam slippage, and needle thread breakage. Each defect
affects the overall quality, productivity, and cost of production. The causes of these
defects are often related to improper handling, machine issues, or inadequate skill.
Remedies focus on better machine maintenance, proper tension settings, and training
operators. It was studied that controlling defects is crucial for improving garment quality
and productivity. He also proved the importance of minimizing rework, which is seen as a
non-productive activity. Identifying and addressing defects early can reduce costs and
meet customer expectations. Analysis of sewing, cutting, and finishing defects in specific
factories shows that effective management can reduce defect rates and improve overall
efficiency [38].

The humans first articles of clothing were prepared by the animal’s skins and their bones
were also used as a needle so at that time defects were minimum but no these are not used
and innovations are come in stitching process so the term “defect” is also come and it is a
major cause in stitching because it effects the quality of garment. There are two major
stitching defects in a textile manufacturing unit, focusing on two critical defects like skip
stitch and stain spot. The skip stitch and stain spot are identified as the most frequent
defects. It analyzes these defects using tools like Pareto charts and Fishbone diagrams.
Skip stitch defects are mainly caused by machine issues (50%), material (25%), method
(15%), and manpower (10%). For stain spots, machine, material, method, and manpower
contribute equally (25%). The paper emphasizes the importance of identifying defects
early to reduce production costs and improve quality. It recommends lean manufacturing
techniques like Lean Six Sigma, and DMAIC to minimize these defects. Defects can be
minimized by just organizing the setup and Little care during the production is carried out
[39].

Dr. Huda et al discussed the importance of improving productivity in apparel

manufacturing. Demand for higher value a lower price is increasing and Surviving
apparel manufacturers need to improve their Operations through producing right first-
time quality and Waste reduction. He studied 32 garments in Apparel Industry in
Bangladesh. Sewing defects, such as broken stitches and skipped stitches, impact overall
productivity and quality. Through an experimental study involving data collection from
industries, statistical tools like bar charts and fishbone diagrams were used to analyze
sewing defects. He also identified factors contributing to these defects, including sewing
tension, fabric handling, and needle selection. It was concluded that while it is impossible
to eliminate all defects, certain measures, such as optimizing sewing tension, can

24
significantly reduce reworks and improve production efficiency. This also shows that
minimizing non-productive activities like reworks leads to better quality products and
overall factory performance improvement [15].

The study focused on reducing sewing defects in garment factories through the DMAIC
(Define, Measure, Analyze, Improve, Control) methodology of Six Sigma. It targeted four
key defects: stains, skip stitches, broken stitches, and slip-out issues. DMAIC tools such
as SIPOC (Suppliers, Inputs, Process, Outputs, Customers), root cause analysis, and
Pareto charts were used to identify major defects and their causes. For instance, poor
thread quality and incorrect machine settings were primary reasons for skip stitches,
while stains were linked to issues like poor machine maintenance and fabric handling.
The study’s solution-oriented approach helped reduce defect rates, such as broken stitches
decreasing from 3.52% to 1.52%. In conclusion, the implementation of Six Sigma tools,
combined with structured maintenance and training, significantly improved garment
production quality, offering valuable insights for the textile industry to minimize defects
and boost productivity [21].

Kropi et al focused on implementing Statistical Process Control (SPC) in the sewing

section of a garment manufacturing company, Silver Spark Apparel Limited, to improve
the quality of trousers. SPC is part of Total Quality Management (TQM), used to monitor
and reduce variations in production processes. It is a powerful technique to control,
Manage, analyze and improve the performance of a process by eliminating special causes
of variation in processes such as tool wear, operator error, errors in measurements. The
authors applied control charts such as X-bar, R charts, and c-charts for both variable and
attribute quality characteristics in the sewing lines. After training the quality teams and
implementing these SPC tools, the rejection rate decreased from 9.141% to 6.4%. This
improvement shows the significance of SPC in controlling process performance and
reducing defects. There are three different ways of SPC tool Implementation like SPC
software, SPC in excel sheet and SPC with manual application [40].

Ismar Hrvacic showed that how Statistical Process Control (SPC) was proposed for
manufacturing process of a defense product manufacturing company, with the aim of
improvement product quality. The production process was monitored from material input
to the final output. The processes were mapped and SPC system was proposed. Control
and capabilities were evaluated using SPC techniques, particularly XR, XS, and p-charts.
XR charts were used when the sample size was between 2 to 10. XS charts were used
when the sample size was above 15. It is an indicator of the consistency and predictability

25
of the level of defects in the process. The companies where the production is at high level
and the companies demand high quality products these companies use SPC tools. His
main focus was to use the control charts which are compound from the 𝑋 𝑅, 𝑋 𝑆 and p-
chart. These charts are the main tools for reducing defects and improving quality. The
importance of SPC in lowering variability and stabilizing output was emphasized, and
control charts offered information for ongoing quality assurance. High-level production
has been demonstrated to benefit from SPC implementation by lowering errors, cutting
production time, promoting steady manufacturing, and improving trade quality. The
design of experiments and control charts were highlighted as crucial SPC tools for
examining and improving production processes [41].

Scott Ellsworth et al studied about paper making industry where they applied SPC with
APC to enhance quality in the textile industry. Specifically, it examines a manufacturing
process for paper maker cloth, where variations in yarn length lead to low product quality.
The key metric is used is the co-efficient of variation (CV), with a target of 0.2% CV set
by benchmarking. The study found that implementing APC helped reduce the CV from
4.6% to 0.8%. However, the process was still unstable according to SPC standards.
Analysis showed that issues such as shift to shift operator differences contributed to this
instability. These differences could be minimized through operator training, which could
further reduce CV by approximately 50%. This showed that combining SPC with APC
could improve quality [42].

The main purpose of Kumar et al was to reduce the defects in Apparel Industry because
they lower the cost of fabric because of poor quality of a product. The study was
conducted at Interstoff Apparels Limited and focused on reducing defects in knit T-shirts.
Key defects identified include broken stitches, open seams, and skip stitches. Using
Pareto analysis, he determined that a few defects accounted for most of the issues,
particularly broken and skip stitches. From Pareto chart it was cleared that Broken stitch
was a major defect in garment industry. The Pareto chart shows that the major cumulative
defects are others (19%), broken stitch (36%), slip stitch (48%), the open seam (59%)To
address these problems, the he applied the 5S methodology (Sort, Set in Order, Shine,
Standardize, and Sustain) and the PDCA cycle (Plan, Do, Check, Act). These tools aimed
to identify root causes and implement corrective actions to improve product quality. He
also proved that continuous monitoring and lean manufacturing techniques can
significantly minimize defects, increase customer satisfaction, and enhance overall
productivity [43].

26
Md. Syduzzaman et al studied TQM principles in a Bangladesh industry to improve the
quality of a product by reducing defects, lowering cost and satisfying the customer. The
study was conducted at a very famous industry knit Asia Ltd. of Bangladesh. They
studied a sewing floor before applying TQM and after applying TQM. So they concluded
that almost 50 defects were reduced by applying TQM. It emphasized that in order to
satisfy quality standards and raise customer satisfaction, Total Quality Management
(TQM), a complete management strategy, required constant improvement across all
divisions. Implementing TQM aims to maintain competitiveness, increase productivity,
and reduce waste. TQM was essential to the Bangladeshi Ready-Made Garments (RMG)
industry, which is essential to the nation’s economy, in order to maintain product quality
and meet the expectations of the international market.

Compared to larger organizations, small and medium-sized businesses (SMEs) had a

harder time implementing TQM, frequently concentrating primarily on ISO 9000
certification. This highlighted the significance of creating a customized TQM framework
and provided insights into the particular TQM requirements for the RMG industry [44].

Research Gap
In many garment industries, advanced tools and techniques like automated sewing
machines with sensors, real-time defect monitoring systems, data-driven quality control
using AI, and lean manufacturing techniques are underutilized. These tools and
techniques are not used in today’s garment industries because of high cost, and limited
technical expertise.

Specific Objectives
 To identify the defects.

 To analyze the defects.

 To reduce defect rate by implementing innovative tools and techniques.

27
28
 References

[1] C. y. liong, "A simulation study on a garments manufacturing process," pp. 460-466, 2015.

[2] M. Mr.R.Surjit, "Apparel Machinery and Equipments," pp. 1-333, 2015.

[3] P.Sarkar, "Garment Manufacturing ProcessFfrom Fabric to Finished Apparel Products," pp.
1-5, 2016.

[4] M. M. Pandit, "Introduction Of Textile," vol. 1, pp. 1-2, 2019.

[5] R. Babu, "Industrial Engineering in Apparel Production," pp. 1-5, 2012.

[6] S. e. al, "Textile Finishing," Journal of Textile and Apparel Technology Manangment, vol. 10,
p. 2, 2017.

[7] S. G. e. al, "Sustainability and Human Resource Manangment in Textile Industry," Journal of
Manangment and Organization, vol. 22, p. 1, 2018.

[8] "Optimization of Sewing Parameters for Improving Quality and Productivity in Garment
Manufacturing," Journal of Textile and Apparel Technology Manangment, vol. 10, no. 3, pp.
1-12, 2018.

[9] S. S. R. e. al, "Common Sewing Defects in Apparel Industry," Journal of Fashion Technology
and Manangment, vol. 11, pp. 1-10, 2019.

[10] M. S. A. T. u. Islam, "Study on different types of defects and thier causes and thier remedies
in garments industry," pp. 300-304, 2019.

[11] H. B. Raluca, "Annals of the University Of Oradea fascicle of textiles, seam puckering
evaluation method for sewing process," p. 14, 2017.

[12] M. Islam, "Analysis of Sewing defects in garment industry: Causes and Remedies," Journal
of Textile And Apparel technology Manangment, vol. 10, 2018.

[13] R. S.S, "Investigation Of Thread Tension Effects on Sewing Performance," Journal of textile
engineering and fashion technology, vol. 4, 2019.

[14] R. Singh, "Impact of needle size on fabric distortion in sewing," Vols. 30,2, 2019.

[15] M. S. A. Tarikul Islam, Study on different types of defects and thier causes and remedies in
garments industry, 2019, pp. 300-304.

[16] A. K. Dey, "Reducing Seam Allowance Related Defects," Vols. 30, No.2, p. 17, 2019.

[17] R. K. Singh, "Statistical Analysis Of Briken Seam Defects in Textile Industry," Journal of
Statisctics and Manangement System, vol. 22, 2019.

[18] M. S. S. R. P. K. S. Patel, "Minimization of defects in Garment During Stitching," 2017.

[19] A. C. Payal Bansal, The study of swing damages and defects in garmenst, 2018, pp. 1-19.

29
[20] A. Choudary, "The study of sewing damage and defects in garments," Research Journal of
Textile and Apparel, p. 19, May 2018.

[21] D. N. u. Huda, "Critical analysis of sewing defects and minimization of sewing reworks in the
apparel industries," pp. 1-6, 2018.

[22] "J. Liu," Journal of Manufacturing System, vol. 10, 2018.

[23] S. Kochar, "All about garment quality auusrance and quality control," pp. 1-7, 2022.

[24] Gaspersz, "Total Quality Management (TQM)," vol. V.2003, 2003.

[25] M. S. Muhammad Ragil Suryoputro, "Quality Control System using Simple Implementation
of seven tools for Batik Textile Manufacturing," pp. 1-11, 2017.

[26] J. Willey, "Fundamentals of quality control and improvements," pp. 1-8, 2016.

[27] Yamit, " Manajemen Kualitas Produk dan Jasa," pp. 1-10, 2010.

[28] A. Singh, "A Study of Seven Tools for Quality Improvement," , pp. 1-6, 2018.

[29] A. Mitra, "Application of Seven Quality Control Tools in Manufacturing Industries," Journal
of Industrial Engineeing, vol. 28, pp. 25-33, 2004.

[30] Z. K. Jelena Jovanović, "Basic Quality Tools in Continuous Improvement," pp. 1-9, 2009.

[31] R. a. J. R. Soni, "Seven Quality Control Tools," International Journal of Quality Research, vol.
10, pp. 251-262, 2016.

[32] R. K. N. G. Singh, "Optimization of Advanced Sewing Machine Parameters for Improved

Efficiency and quality," Journal of Textile and Apparel Technology, vol. 11(2), pp. 1-15, 2022.

[33] P. K. S. Kumar, "Smart Defect Detection System for Garment Industry using IoT Based
Sensors," vol. 12(1), pp. 1-12, 2022.

[34] A. K. S. e. al, "Development of an Automated Grading System for Garment Industry,"

Journal of Fashion Marketing and Manangment, vol. 24(2), 2020.

[35] R. R. K. e. al, "Real Time Thread Tension Monitoring and Control system for Sewing
Machines," Journal of Clothing Science and Technology, vol. 31(2), 2019.

[36] "Copmuter Aided Design and Simulation of Garment Draping," Journal of Fashion in
Marketing and Management, vol. 24(2), 2020.

[37] F. Taddesse, "Minimization of defects in sewing section at garment and textile factories
through DMAIC metholody of 6 sigma," pp. 1583-1637, 2017.

[38] R. R. Kumar, "Turn over issues in the textile industry in Ethiopia," African Journal of
Marketing Management, vol. 3(2), pp. 32-44, 2011.

[39] S. K. U. K. M. Pawan Kumar, Identification and analysis of stitching defects at the stitcing
units, 2021, pp. 373-383.

[40] Y. H. a. L. Mulat Alubel, "Implementation of statistical process control in the sewing section
of garment industry for quality improvement," pp. 160-171, 2018.

[41] I. Hrvačić, "Design and Implementation of SPC Systems in Defense Industry," vol. 6(1), pp.

30
 27-40, 2018.

[42] T. A. a. K. B. D. H. Scott Ellsworth, "COMBINING SPC WITH APC TO IMPROVE QUALITY," vol.
10(3), pp. 575-578, 2014.

[43] M. R. Samrat Kumar, "Minimization of sewing defects of an apparel industry in Bangladesh

with PDCA," pp. 18-24, 2018.

[44] M. M. I. M. A. H. Md. Syduzzaman, "Effects of Implementing TQM Principles in the Apparel

Manufacturing Industry: Case Study on a Bangladeshi Clothing Factory," vol. 6(3), pp. 68-75,
2016.

31
`1

32