Root Causes for Over Stitch at Sewing Line in Garments Industry

 

Root Causes for Over Stitch in the Sewing Line — Identifying Key Factors Behind Stitch Overshooting and Ensuring Quality Control in Garment Production.

Over stitch is a common sewing defect in the garments industry that occurs when operators sew beyond the intended stopping point or seam line. This defect not only affects the appearance of the garment but can also lead to rework, fabric damage, and production delays. The root causes of over stitch usually include operator carelessness, improper machine speed settings, unclear seam markings, lack of supervision, and inefficient workstation setups. Identifying and addressing these issues through proper training, clear guidelines, and continuous in-line quality control can significantly reduce over stitch occurrences and improve overall sewing quality.

1. Operator-Related Causes

·         Operator’s lack of attention or carelessness during sewing.

·         Improper handling of fabric panels, especially at the end of seams.

·         Lack of training or poor understanding of seam allowance and markers.

·         Sewing at high speed without control, leading to overshooting.

·         Not following operation standard or SOP (Standard Operating Procedure).

Preventive Actions:

·         Train operators to stop exactly at the mark or notch.

·         Encourage slower speed at seam ends.

·         Use visual markers or guides at seam end points.

·         Continuous monitoring by line QC.

2. Machine-Related Causes

·         Improper machine speed setting (too high).

·         Faulty pedal control — if the pedal response is too sensitive.

·         Thread tension or feed issues causing seam slippage.

·         Lack of needle guard or stitch guide at the edge.

Preventive Actions:

·         Adjust machine speed as per operation type.

·         Calibrate the pedal for better control.

·         Ensure proper machine maintenance and alignment.

·         Install edge guides to help stop sewing at the correct point.

3. Marker or Guideline Issues

·         Unclear marking or missing seam-end indicators.

·         Improper fabric cutting resulting in mismatched edges.

·         Inconsistent seam allowance between panels.

Preventive Actions:

·         Ensure clear marking of seam start and stop points.

·         Improve pattern cutting accuracy.

·         Use visible chalk or notches to identify seam boundaries.

 

4. Supervision & Process Control Issues

·         Lack of line supervision or improper in-line checking.

·         Absence of operation layout control and process discipline.

·         No feedback system from finishing or audit stage to sewing line.

Preventive Actions:

·         Assign skilled QC for in-line monitoring.

·         Implement defect tagging and feedback system.

·         Conduct regular process audits to identify operator error trends.

 

5. Workstation Layout & Handling

·         Improper work aids (guides, folders) not used properly.

·         Uncomfortable workstation setup, causing poor handling.

·         Improper bundle system, leading to confusion of matching parts.

 

Preventive Actions:

·         Use suitable work aids (guides, folders, stoppers).

·         Set up ergonomic workstations.

·         Maintain proper bundle system and part identification.