How to Remove Defective Parts or a Ply from the Lay?
Question: How to deal with the problem when we got holes in layering? ... asked by Fitsum.t
It is normal that you may found defects like holes or cut in the fabric at the time of layering. But defective garment components should not move or pass to stitching floor. In this article, I have explained the way how you can resolve this issue.
The standard procedure of fabric checking is to mark holes or other defects with a red sticker or visible coloured chalk. It is done this way so that layer-men know where in a layer a defect is located. Once defects are get noticed based defect size a layer-man take decision on how to handle defective layers. If your fabric checker does mark the defects in the fabric during checking, ask them to follow this method. Otherwise, layer-man can skip defects at the time of layering and there is a chance of having bundles with defective panels.
When you found holes in a fabric layer during spreading of the fabric you have two options to get cutting without holes or remove defective parts from bundles.
1. When layer-men notice holes in a layer, cut the fabric across the width at the hole and do splicing of layers. In this method, your fabric consumption will increase a little bit but you don't get cut component without holes on it. And no need to change parts later.
2. Lay fabric as it is. I mean with defects. Put a coloured fabric strip across width and length of the lay on holes. Later when you do shorting of cut panels, reach to the defective panel through coloured strip, remove it from the bundle and replace it with new panels. When you replace a component be careful to cut a component from end bits of the same fabric lot to avoid shade variation in a garment.