How to change defective or damaged garment parts intelligently?

“Part changing” is not an intended process in garment manufacturing but this process is there because there is certain reasons where we can’t control the cause of fabric damages in the garments completely. However, where possible, we have to minimize short shipment and improve our sales. Part changing is generally done in finishing stages. Most of the fabric defects that are not acceptable in garments are removed during cutting and stitching processes. Still damaged part is found in the sewn garment due to heavy washing, dyeing or other reasons.

Instead of rejecting the defective garment, only damaged part can be changed and converted it into a quality garment.When part changing is necessary and main purpose of the part changing is to improve ship quantity, part changing must to be done intelligently. It should not increase the fabric consumption or produce further defective garment in the part changing process. You have to think from where you will get fabric for part changing? How to remove damaged component and re-stitch the garment maintaining sewing quality?

For the fabric usage you have multiple options – i) End bits of the cut layers, ii) using fresh fabrics or iii) replacing damaged parts with good parts of another garment. Which option to be chosen is depends on garment processing after stitching, fabric types, value added work or embellishment in the garment.

End bit usage for part changing:

In the cutting room, during layering cutters store end bits that are not layered in the lay for a cutting. These end bits are one type of cutting waste. So for the part change you can use those end bits without increasing fabric consumption. But here you have to take care about shade matching or lot matching of the fabrics with the damaged garments. If the garments were heavily washed, then it will be very difficult to match the garment fabric shade. After changing the parts garment must be washed again to give matching finished look and similar hand feel.

Fresh fabric usage for Part changing: 

If you don’t have enough end bits to replace the damaged parts from the garment, use available fresh fabric. When using fresh fabric, you may find problem with shade matching, extra fabric consumption for the order. Only use fresh fabric if there is no problem with shade matching. But for solid colors and yarn dyed fabric there is no issue related to shade matching.

Using good components from other damaged garments: 

This option is chosen when garments are dyed and there are no fresh fabric or end bits or fresh fabric for that order. The reason, instead of rejecting all garments, you can make some good garment losing few garments. Also for the high value garment with fine hand embroidery work and where you have less time to complete the shipment, this option is preferred. Like above options, you have to care about the garment component’s shade matching.