Defect Classification & Severity Assessment Protocol
Classify garment defects using ASTM D6775 & ISO 11971 standards for defensible QA decisions
What You Can Do
You can rapidly categorize defects by type, severity, and impact using industry-standard nomenclature that withstands supplier disputes and audit reviews. This skill helps you generate defensible inspection documentation, train QA teams on consistent grading criteria, and build defect trend analysis to drive corrective actions and supplier accountability.
Features
Categorize by construction (seams, hems), appearance (color, print), structural (tears, holes), and finish issues using ASTM D6775 nomenclature
Rate defects as critical, major, or minor based on ISO 11971 standards and brand/retailer specs for consistent pass/fail decisions
Generate inspection reports with clear defect descriptions, location mapping, and photo reference protocols that survive audits
Link defect patterns to specific suppliers, production dates, or line numbers to identify systemic issues requiring corrective action
Calculate defect rates (PPM, percentage) and trending metrics for performance reviews and vendor management
Build calibration guides and acceptance/rejection examples to train new QA staff on consistent grading
Apply rule-based criteria to determine shipment disposition with clear justification for credit memos or rejection notices
Track recurring defects across production runs to prioritize corrective action planning and supplier feedback
Example Output
Example 1: Incoming Inspection Report
Defect ID: SEW-001 | Type: Seam Puckering | Severity: Major | Location: Front shoulder seam
Description: Visible wave pattern along shoulder seam, 3" length
Standard: ASTM D6775 (Appearance Defects) — Major per brand spec
Decision: HOLD — Requires seam rework or full lot rejection
Supplier: XYZ Apparel | Production Date: 2025-01-15
Example 2: Defect Trend Summary Seam puckering defects: 8 occurrences across 5 shipments (Jan–Feb), primarily from cutting line #2. Recommendation: Recalibrate serger tension and inspect raw material shrinkage.
Example 3: Inspector Calibration Guide Defect: Color bleeding | Critical if: Dye transfers to skin or adjacent colors. Major if: Visible only under wet conditions. Minor if: Detectable only with lab test.
What's Included
- SKILL.md: Complete defect classification protocol with ASTM D6775 and ISO 11971 reference mappings
- Defect Type Matrix: Standardized categories (construction, appearance, structural, finish) with severity criteria
- Inspection Report Template: Pre-formatted fields for defect documentation, photo reference, and hold/ship decisions
- Inspector Calibration Checklist: Training guide with accept/reject examples and visual defect references
- Defect Trend Analysis Worksheet: Monthly tracking template for PPM calculations and corrective action planning
Who It's For
- Quality Assurance Managers — Standardize defect grading across inspection teams and production runs
- Production Supervisors — Document defects defensibly for supplier communication and corrective actions
- Incoming Inspection Inspectors — Apply consistent, standards-aligned criteria for pass/fail decisions
- Supplier Quality Engineers — Investigate root causes and build performance improvement plans
- Brand/Retailer Compliance Officers — Audit defect documentation for audit readiness and contractual compliance
Best For
- Incoming fabric roll and cut piece inspection with clear severity grading
- Finished garment inspection with defect documentation for hold/ship decisions
- Supplier scorecarding and corrective action notice preparation
- QA team training and inspector calibration on defect recognition standards
- Defect trend analysis for root cause investigation and production line improvements
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