Defects · TexFlow ERP

Defect register

Every defect linked to a department, order and root cause

Defect	Department	Style	Order	Qty	Severity	Root cause	Status
Open seam — side slit	Sewing line 09	HOOD-3021	PO-2062	184	Major	Operator skill on heavy fleece	CAPA open
Oil mark	Sewing line 04	POLO-2048	PO-2048	86	Minor	Machine over-oiling after service	In progress
Loose thread	Finishing bay 2	POLO-2048	PO-2048	120	Minor	Trimming station understaffed	Rework RW-2048
Needle damage	Sewing line 01	TSHIRT-1024	PO-2051	64	Major	Blunt needle, change interval missed	Closed
Shade variation	Fabric store	POLO-2048	PO-2048	78 kg	Critical	Dye house batch variation	Rejected to vendor
Print registration	Printing vendor	TSHIRT-1024	PO-2051	88	Major	Screen alignment at vendor	Charged back
Measurement out of tolerance	Sewing line 09	HOOD-3021	PO-2062	42	Major	Pattern shrinkage allowance	CAPA open
Collar shape	Sewing line 04	POLO-2048	PO-2048	148	Major	Rib tension at collar attach	Rework

Open seam23%

Oil mark17%

Loose thread13%

Needle damage10%

Shade variation8%

Others29%

Fixing the top three defect types would lift first pass rate to about 93%.

Sewing62%

Printing14%

Finishing12%

Fabric8%

Cutting4%

₹4.86L

Equal to 0.4% of monthly revenue.