A precise made-to-measure (MTM) system for producing Korean Air Force winter uniform slacks was recently developed and introduced in 2012 to reduce the rate of defects. However, a further reduction in defects with the conventional MTM system has become increasingly difficult. In this study, it was hypothesized that the major causes of defects were closely related to anthropometric factors. Hence, various statistical analyses were performed to solve this problem. Body scan data from a large number of soldiers were analyzed to categorize the shapes of the lower body. Defective garments were then analyzed to determine the anthropometric measurement associated with most defects, after which they were manually adjusted to fit the subject. Subsequently, by using a simple regression analysis, the relationship between the adjustment and related anthropometric measurement was investigated. Finally, an automated anthropometric data adjustment system was developed to provide appropriate size data to the automated pattern generation system.