Sewing Defects

Defects in this category

• S-01

  Skip stitch

  Classification guidance

  buyer defined

  Detection stage

  Inline sewing audit and final workmanship inspection

  Immediate containment

  • Stop the affected operation
  • Segregate units since the last confirmed good check

  Disposition

  Repair and reinspect where allowed; classify by seam function, location and buyer criteria.

  Evidence to retain

  • Operation and machine ID
  • Unit traceability
  • Repair and reinspection record

  Common causes

  • Wrong needle
  • Thread tension imbalance

  Prevention

  • Needle/thread matrix
  • Daily tension check

• S-02

  Broken stitch

  Classification guidance

  buyer defined

  Detection stage

  Inline, end-line and final workmanship inspection

  Immediate containment

  • Contain the affected production window
  • Check the machine for burrs and thread damage

  Disposition

  Repair when integrity can be restored; escalate functional or safety-sensitive seam failures.

  Evidence to retain

  • Seam location
  • Machine and operator ID
  • Thread and needle details

  Common causes

  • Weak thread
  • Sharp burrs on throat plate

  Prevention

  • Thread strength QC
  • Machine maintenance

• S-03

  Puckering

  Classification guidance

  buyer defined

  Detection stage

  End-line appearance review after pressing

  Immediate containment

  • Hold the affected operation output
  • Preserve approved appearance samples for comparison

  Disposition

  Adjust the process, then repair or reject according to appearance limits in the buyer manual.

  Evidence to retain

  • Seam and panel location
  • Approved appearance reference
  • Machine setting record

  Common causes

  • Feed imbalance
  • Fabric handling

  Prevention

  • Presser foot pressure setup
  • Operator training

Decision guidance

Prioritise defects by frequency and downstream cost, not by severity alone. Use the causes listed above to drive root-cause analysis and the prevention actions to build standing containment in your process. Verify each corrective action with a post-CAPA audit before closing.