Defect Reduction in Textile Manufacturing: A Review

The textile industry faces continuous challenges in reducing defects during manufacturing, as quality inconsistencies can lead to financial losses, reduced efficiency, and diminished consumer confidence. Addressing this issue requires a combination of methodological and technological approaches that optimize production while minimizing waste. This review examines various strategies for defect reduction, focusing on process improvement methodologies, predictive technologies, and sustainable practices. A systematic analysis of 12 studies highlights the effectiveness of structured quality management approaches in identifying and eliminating defect sources. Additionally, predictive models based on artificial intelligence have demonstrated significant potential in real-time defect detection and prevention, improving overall product quality. However, challenges such as machinery rigidity and the high variability of textile products complicate the implementation of these strategies. Sustainable manufacturing practices and specialized workforce training have also been identified as key factors in enhancing defect management, as they contribute to resource conservation, waste reduction, and improved working conditions. The findings suggest that a comprehensive approach, integrating advanced process optimization techniques, predictive analytics, and sustainable production methods, is essential for improving efficiency and quality in textile manufacturing. This integration not only reduces defects but also strengthens competitiveness in an industry increasingly driven by quality, sustainability, and technological innovation. The OSF registration can be accessed at: https://doi.org/10.17605/OSF.IO/NAMWY. © 2025 IEEE.