Scratches, frayed edges, loose threads, and wrinkles are often classified as minor garment defects during factory production. However, even seemingly minor defects can lead to costly returns, rejected shipments, negative reviews, and damaged retailer relationships.
Garment defects can arise at any stage of manufacturing if rigorous quality assurance protocols are missing. Implementing professional on-site apparel and garment inspections before shipment is critical to verifying that products fully comply with buyer specifications and international quality standards.
Based on field inspection data compiled by GIS Inspection specialists across soft-line categories, including T-shirts, coats, jeans, jackets, and skirts, GIS has identified the top 10 most common garment defects found during apparel and garment inspections in China
1. Untrimmed Thread End
Main Causes:
- Excess sewing threads are not properly trimmed after the stitching operation.
- Inadequate thread trimming during the garment finishing process leaves loose or visible thread ends.
- The severity of the defect may depend on the thread length and location, according to the applicable quality standard.
Solution:
- Inspect garments after sewing and finishing for loose or untrimmed thread ends.
- Trim excess threads before packing and shipment.
- Check both the exterior and relevant interior areas of the garment.
- Follow the buyer’s specifications, approved sample, or applicable quality standard for thread-trimming requirements.
2. Dirty Mark
Causes:
- Textiles can never be truly protected from stains because they can appear at any time during or after production if they are not stored in an area with adequate protection.
- Stains can appear on fabrics from almost any source: dirt from the plant, oil from the sewing machine, and dyes.
- Stains are relatively easy to identify and prevent if suppliers keep a close eye on the quality of fabric.
Solution:
- A manufacturer can prevent stains during production by regularly cleaning production machines and equipment to ensure no random oils, grease, or dyes make their way onto the textile.
- Wrapping the finished rolls of fabric in plastic and storing them in a separate area away from the dying area can help avoid post-production stains.
3. Poor Ironing
Main Causes:
- Garments are poorly pressed during the finishing process, leaving visible wrinkles, crease marks, or an untidy appearance.
- Improper pressing may also result in seam impressions, shine marks, or stretched and distorted garment shapes.
Solution:
- Check the overall appearance of garments after ironing.
- Ensure garments are properly pressed before packing and shipment.
- Check seams, pleats, folds, and other garment details for correct pressing.
- Check for wrinkles, crease marks, seam impressions, shine marks, and shape distortion.
4. Color Fly Yarn
Main Causes:
- Yarns with an incorrect or unwanted color are visible in the fabric.
- The contrasting yarn creates a visible color irregularity in the fabric appearance.
Solution:
- Check the fabric surface for yarns with incorrect or contrasting colors during inspection.
- Remove or replace the affected yarn where the production process allows.
- Check the fabric appearance against the approved sample and buyer's color requirements.
5. Misaligned Seam
Main Causes:
- Seams do not line up correctly or cross the specified point.
- Poor fabric handling, inadequate marking, or improper alignment of garment pieces can cause seam misalignment.
Solution:
- Use proper marking and alignment methods before stitching.
- Ensure garment pieces are correctly matched and aligned during sewing.
- Check seam junctions and other key construction points during inspection.
6. Skipped Stitches
Main Causes:
One needle is broken or cannot work normally when knitting
Solution:
- Use high-quality needles on the knitting machine
- Checking the yarn holder and any other machines for proper tension during production can prevent stitches from falling.
7. Snarled Stitches
Main Causes:
- Improper tension – The upper thread or bobbin thread tension is incorrectly adjusted, preventing the threads from tightening or interlocking properly.
- Debris in the bobbin area – Thread ends, lint, or other debris may be tangled in the bobbin area, interfering with normal thread movement.
- Bobbin thread running low – When the bobbin thread is nearly used up, it can also cause abnormal stitch formation.
Solution:
- Re-adjust the upper and bobbin thread tension to ensure it meets the machine's requirements.
- Clean the bobbin area to remove accumulated thread ends, lint, and other debris.
- Replace or rewind the bobbin promptly to avoid operating with a nearly empty bobbin.
8. Knots
Causes:
Fly fiber fell on the yarn when spinning. Or untrimmed coarse yarn when weaving.
Solution:
- Ensure proper maintenance and cleaning of machines and the production environment.
- Neps can be removed before processing.
9. Pleated Mark
Causes:
- The flap assembly of two fabric pieces is imperfect (twist effect).
- The press teeth of the sewing machine is too tight.
Solution:
- Improve the worker’s skills and adjust the press teeth.
10. Wrinkle Mark
Causes:
Main Cause
- Visible wrinkles or crease marks remain on the garment surface.
- Wrinkle marks can occur as a finishing or pressing-related appearance defect.
Solution:
- Inspect the garment surface for visible wrinkles and crease marks.
- Ensure garments meet the required appearance standard after finishing.
Conclusion
With over 20 years of experience in quality assurance, GIS Inspection is ready to help your business in the apparel and textile industry with quality control services. We offer a wide range of curated services for clothing, including factory inspection, pre shipment inspections and container loading supervision and more.
Get in touch with us today to find out how we can help you navigate your current apparel quality control challenges.
