The garment manufacturers are hard pressed with continuously reducing product lead-time and improving productivity and quality of their products. To satisfy these requirements fabric should conform to the specification and the standard developed by the industry. But in reality it is difficult to find perfect fabric that exactly sticks to the standard. In spite of the huge advancements made in textile manufacturing technology during last several centuries, textile industry is not able to produce 100% perfect textile materials that constitute 65% - 70% of the cost of the garments. Industries, which utilize the textile materials, are to face difficulties to control the impact of the defects in the fabric.


For proper costing of a garment, and cost reduction, it is necessary to have good understanding of the fabric quality and various fabric losses that occur during garment production. It is possible to find a lot of papers and research works based on improving the marker efficiency to minimize the fabric losses but very few work or research has been done to reduce the impact caused by fabric defects.


For evaluation of fabric quality that cannot be directly reviewed are to be tested at sophisticated textile testing laboratories. If the testing results are matched with the general acceptable standard of shrinkage, colour fastness, seam strength, tensile strength, colour fastness to crocking etc., which are known as Latent Defects, garment manufacturers can continue production with out difficulties. But the defects occurred in fabric weaving, dying and finishing which can be reviewed visually known as Patent Defects (knots, holes, slubs, stains, fly yarns, yarn fault etc.,) have different effect of the losses for different garment styles even though that fabric meet the quality standard of these defects.


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The author holds M.Phil and is a freelance consultant.