Root Causes for Down Stitch at Sewing Line in Garments Industry
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| Root Causes for Down Stitch in the Sewing Line — Identifying Key Factors Behind Uneven or Misaligned Stitching in Garment Production. |
Description:
Down stitch in the sewing line occurs when the operator sews beyond the designated stitching line or lower than the correct seam position, causing uneven seam appearance and shape distortion. This defect is often the result of operator inattention, improper fabric handling, inaccurate guideline marking, or poorly adjusted sewing machines. To minimize down stitch issues, factories should ensure clear seam markings, maintain proper machine calibration, provide operator training on control and accuracy, and strengthen in-line supervision. Effective process discipline and regular QC monitoring can significantly reduce such stitching defects and improve overall garment quality.1.
Operator-Related Causes
- Operator fails to stop the machine exactly where the
previous stitch ended.
- Poor control during restart after thread breakage.
- Lack of awareness about joining technique after
re-threading.
- Inattention or fatigue during continuous operation.
đ Preventive Actions:
- Train operators on correct start–end overlap control
(2–3 stitches only).
- Supervise closely during new style setup.
- Ensure adequate rest breaks to avoid fatigue.
- Implement inline checking by quality inspectors.
2. Machine-Related Causes
- Poor thread tension causing frequent thread breakage.
- Improper synchronization between needle, feed dog, and
hook.
- Faulty or blunt needle causing skipped or broken
stitches.
- Auto-trimmer malfunction leading to uncut threads or
restart errors.
đ Preventive Actions:
- Check machine tension and timing regularly.
- Replace worn-out needles and trimmers.
- Conduct daily machine maintenance and trial run before
production.
- Adjust thread path and lubrication as per fabric type.
3. Thread-Related Causes
- Inferior or incompatible thread quality.
- Wrong thread size or type for the fabric.
- Improper winding on bobbin causing inconsistent
feeding.
đ Preventive Actions:
- Use buyer-nominated or tested thread.
- Match thread size to needle and fabric.
- Ensure bobbins are wound properly with consistent
tension.
4. Fabric-Related Causes
- Slippery or elastic fabric moving irregularly during
restart.
- Fabric puckering or distortion causing operator
misalignment.
- Unstable seam area after first stitching.
đ Preventive Actions:
- Use fabric guides and seam stabilizers when needed.
- Control feed ratio to reduce seam shifting.
- Check seam holding after first pass before restart.
5. Process & Line Management
Causes
- No standard procedure for handling re-stitching after
breaks.
- Improper quality checkpoints for stitch continuity.
- Pressure for high output leading to careless rejoining.
đ Preventive Actions:
- Set clear SOP for handling joint or broken stitch
correction.
- Conduct inline audits for re-stitched garments.
- Balance workload to reduce operator stress.
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