9 Step Guide to Eliminate Fabric Shade Variation in Garments

SHARE:

Shade variation is one of the common problems found in garments that are made of dyed or printed fabrics. A garment with shade variation is considered as a faulty garment. Shade variation in a garment is occurred when different garment components have different depth of colors (shade) or mismatch of shades in garment parts of a same garment. Shade variation in garment comes due to shade variation in fabric of an order. Most of the time shade variation happened due mishandling of fabric rolls during cutting fabrics and bundles in sewing floor.

Shade variation in garments is caused mainly due to fabric problem. Then why varied shades of fabrics are sourced by garment manufacturers? Fabrics are dyed in dyeing machine that has a certain capacity of dyeing fabrics at a time. So, where fabrics are dyed in multiple lots, there is chance of having shade variation between different fabric lots if dyeing process is not controlled.

Shade variation in fabric may appear as
  • Within same fabric roll there may be shade variation like 'center to selvage' and 'salvage to salvage'
  • Within same fabric roll length wise shade variation 
  • Shade variation in between fabric rolls

Shade variation in garments (between different components of the same garment) can be controlled if a SOP is set and employees follow that SOP to reduce shade variation in garments. From fabric inspection to garment finishing in each step you have to be pro-active and take action to prevent shade variation in finished garments.

Considering that you can't do much in fabric quality. In such situation how to eliminate or reduce shade variation in garments?

In this article I will show you step by step guides and give you tips to eliminate or at least you can reduce shade variation in garment production.

Tips to reduce and control shade variation in garments:

  1. Fabric inspection: Whether it is in-house dyeing or dyed fabric from outside processors, all fabric rolls need to inspect for shade variation. Categorize fabric rolls based on fabric shades.  If there is a wide range of shade variation and fabric shade is out of the standard one, you can reject that lot and sent back rejected to your fabric processors for re-processing.

  2. Preparing Shade band: Develop shade bands and get approval for all shade bands you have in your bulk fabric. Mark shade band no. to each fabric roll / than. Shade bands help in fabric layering and shorting in cutting room.

  3. Communicate with clear information: When you have an order with varied shades of fabrics, information must be shared with cutting department as well as production department. While issuing fabric to cutting, intimate cutting department that fabric has different shades and fabric lots should not be get mixed.

  4. Fabric layering: As advised in point#2, you have to categorize rolls according to shade band. While spreading fabrics for cutting, spread fabrics of same shade band no. in a lay. Don't mix fabrics roll of different shades. When you need to spread fabric of another shade on the same lay place separator to identify cutting of different rolls easily at the time of shorting and bundling. 

  5. Marker placement: In case fabric has shade variation of 'center to selvage' and 'side to side' place garment pattern on the fabric layer in such a way that shade variation would not be prominent (visible) in garment. Like you can set markers as 'one garment one side' and 'side to side' marker

  6. Numbering of layers: Use ply numbering system and number all garment components. Like, all components of a garment should have same sequence number. In case you spread fabrics of multiple lots in a same lay (cut) use separator for each rolls/ lots. Then while you make bundles make separate bundles for each lots/rolls 

  7. Bundle movement in sewing: After following above steps strictly, one even have shade variation in garment if bundles are not maintained in sewing lines. Sewing operators need to close bundles after completing sewing of a bundle. Ensure that when operators join two component they should check ply number on sticker and sew component with same ply numbers.

  8. Replace defective garment part: Check garment component shade variation at the end of line inspection (at the end of sewing process). Garments found with fabric shade variation (varied shade of different components if that is not a design feature) need to be separated from the good garments. Later defective garments (due to shade variation) can be corrected by replacing parts. For the part changing, be careful to cut parts from the matching lots. 

  9. Single piece garment bundling: If you can't stop ply mixing in sewing you can introduce single piece bundle system in production. In this system, there is no way to sew garment components form different fabric plies. I am not suggesting you to change your bundling system but just showing you an option for getting rid off shade variation problem in finished garments. 
Above steps are not difficult to implement in garment production. Try it yourself and share with us how you have improved and handled shade variation issue in your factory.

[post_ads_2]

COMMENTS

You may also like

Name

5S,3,apparel industry,56,apparel news,33,Apparel Production,30,Apparel Software,15,Bamboo Fabric,1,Bangladesh,1,Blogs,1,Books,30,Business Guides,9,Buyer,1,Buying House,4,CAD/CAM,1,Calculation & Formula,1,career,33,Change Management,1,Clothing,1,Clothing Brand,3,Compliance,3,Consumption,4,Costing,7,Cutting,17,Denim,3,Directory,2,Dyeing,1,eCommerce,1,Education,5,Event & Fair,14,Fabric,70,Fashion,5,Fashion Business,36,Fashion Design,3,Fashion Show,1,Fiber,1,Finishing,10,Garment Exporters,1,Garmenting,1,Gartex,1,Guest Post,8,Human Resource,2,Industrial Engineering,208,Infographic,5,Knitting,3,Kurti,1,Lean,27,Line layout,3,Machines,28,Manufacturing,51,Merchandising,101,MIS,23,MISC,20,Operation bulletin,14,Operator,1,Performance rating,1,PLM,2,Printing & Embroidery,11,Problem Solving,1,Production Planning,26,Project Report,1,QNA,120,Quality,61,Quality manual,2,Quality system,14,Resources,42,Retailing,3,Salary & Wages,7,Sampling,22,Scheduling,3,Sourcing,8,Spec Sheet,9,Sportswear,1,Stitching,3,Store,2,Stretch fabric,1,sustainable clothing,7,T-shirt,3,Tailor,1,Tailoring Shop,2,Technology,56,Texprocess,1,Textile processing,11,Textile testing,21,Textiles,41,Threads,1,Towel,1,Trims & Accessories,15,videos,11,Waste,1,Work Study,38,Yoga wear,1,
ltr
item
Online Clothing Study: 9 Step Guide to Eliminate Fabric Shade Variation in Garments
9 Step Guide to Eliminate Fabric Shade Variation in Garments
Steps to take to eliminate shade variation.
https://4.bp.blogspot.com/-uOCZmuaTlcQ/Ul0xBNu8pyI/AAAAAAAABaQ/wZmQjcwIDTU/s640/fabric+shade+variation.png
https://4.bp.blogspot.com/-uOCZmuaTlcQ/Ul0xBNu8pyI/AAAAAAAABaQ/wZmQjcwIDTU/s72-c/fabric+shade+variation.png
Online Clothing Study
http://www.onlineclothingstudy.com/2013/10/9-step-guide-to-eliminate-fabric-shade.html
http://www.onlineclothingstudy.com/
http://www.onlineclothingstudy.com/
http://www.onlineclothingstudy.com/2013/10/9-step-guide-to-eliminate-fabric-shade.html
true
6551124471002606808
UTF-8
Loaded All Posts Not found any posts VIEW ALL Readmore Reply Cancel reply Delete By Home PAGES POSTS View All RECOMMENDED FOR YOU LABEL ARCHIVE SEARCH ALL POSTS Not found any post match with your request Back Home Sunday Monday Tuesday Wednesday Thursday Friday Saturday Sun Mon Tue Wed Thu Fri Sat January February March April May June July August September October November December Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec just now 1 minute ago $$1$$ minutes ago 1 hour ago $$1$$ hours ago Yesterday $$1$$ days ago $$1$$ weeks ago more than 5 weeks ago Followers Follow THIS CONTENT IS PREMIUM Please share to unlock Copy All Code Select All Code All codes were copied to your clipboard Can not copy the codes / texts, please press [CTRL]+[C] (or CMD+C with Mac) to copy