IGen Global took upon itself to address and solve one of the most common and difficult problems of the sewing industry – the problem of loose stitch, which occurs due to the machine running without under/bobbin threads. The company has come up with a solution called Dr Sewing, a digital under-thread detector that informs (through alarms and light lamp), the operator to change the bobbin thread before it finishes and automatically stops the sewing machine when the operator changes the bobbin. This prevents the ‘loose stitch’ and thus saves cost and time that would otherwise be wasted in medling the defect manually.
Dr Sewing consists of a digital detector, a compact device, which senses the remainder of the under thread through a bar-coded bobbin. In addition, it provides a personal and single/multiple separated winding machines to wind threads on bar coded bobbins separately. The advantages of Dr Sewing include accuracy – to ensure the exact time to stop, convenience – no pre-setting is required, adaptability – it can be installed in mostly all types of sewing/embroidery machines, safety – it assures physical safety of the operator as well as product safety from skip stitch or broken needle parts, and economy – low cost and high efficiency.
Of the visible effects in a factory when using Dr Sewing, the most primary is the productivity going up by 25%, thereby reducing the work cost by 0.47%. In addition, it prevents loose stitch, saving sewing thread cost by 0.08%, and removes defects, hence saving on the cost of rate of defect by 2.30%. There is an overall impact to the production cost rate of 2.85%.