Root Causes for Run-off Stitch at Sewing Line in Garments Industry

Run-off stitch is a common sewing defect in the garments industry, occurring when stitching continues beyond the intended seam end point. This leads to poor appearance, uneven seam finishing, and sometimes rejection in quality audits. The main root causes include operator inattention, high sewing speed, improper machine control, unclear seam-end markings, and lack of supervision. To prevent this issue, operators should be trained to stop exactly at the notch or marker, machines should be properly calibrated, and clear guidelines must be provided. Continuous in-line QC monitoring and proper use of work aids can significantly reduce run-off stitch defects in production.

1. Operator-Related Causes

• Failure to stop sewing at the exact seam endpoint.
• Poor control when guiding fabric at the end of the seam.
• High sewing speed leading to delayed machine stop.
• Lack of marking or reference point for the seam end.
• Inattention or lack of skill in controlling run-off prevention.

👉 Preventive Actions:

• Provide operator training on precise start-stop control.
• Reduce machine speed for critical operations.
• Use clear fabric markings or guides for seam endpoints.
• Conduct frequent in-line checks for operator consistency.

2. Machine-Related Causes

• Machine pedal sensitivity too high, making it hard to stop instantly.
• Defective brake mechanism causing late needle stop.
• Improper feed dog or needle bar control.
• Malfunctioning thread trimmer or sensor delay.

👉 Preventive Actions:

• Adjust machine pedal response and stopping position.
• Maintain machine brake and clutch system regularly.
• Calibrate thread trimmer timing.
• Use needle-position control devices for automatic stop at seam end.

3. Fabric-Related Causes

• Slippery or lightweight fabric moves forward easily, exceeding stitch limit.
• Elastic or stretch fabric elongates during sewing.
• Uneven fabric feeding at seam junctions.

👉 Preventive Actions:

• Use proper feed mechanism (differential feed for stretch fabric).
• Apply seam guide or folder for fabric control.
• Adjust presser foot pressure according to fabric type.

4. Work-Aid & Attachment-Related Causes

• Improper folder, jig, or guide setting causing wrong fabric alignment.
• No physical stop guide at the end of seam.
• Worn-out attachment not holding fabric properly.

👉 Preventive Actions:

• Set proper seam guide or edge stop on machine bed.
• Calibrate folder and jig alignment.
• Replace worn-out or loose work aids.

5. Process & Line-Management Causes

• No defined standard operation procedure (SOP) for seam start and stop control.
• Line balancing issues pressuring operators to sew too fast.
• Lack of in-process inspection for seam accuracy.

👉 Preventive Actions:

• Establish clear SOP and visual standard for seam endpoints.
• Maintain proper line balance and work pace.
• Implement in-line QA checking system.