Optimization for sewing machine setup using experimental design technique

Abstract

The objective of the research was to identify the optimized thread tensile values for the setup of Model D – We 1218-55 computerized 18-needles sewing machine, in order to minimize a number of times the machine halts. The cause of the sewing machine halting, which reduced the efficiencies of the machine, was found to be torn threads. In order to maximize the efficiencies, the experimental design technique was utilized to find the optimal values for five types of cloth: polo, tc-cool, cotton, jacket, and shirt. The method involved three nested designs which are the type of thread, number of sewing layers, and thread-hole size. The three thread tensile levels experimented were low (2 oz.), medium (5 oz.), and high (8 oz.), and the response was the number of times the machine halted in the span of 30 minutes. The ANOVA (Analysis of Variance) used for the experimental design showed that the three factors significantly affected the machine’s halt. The number of times the machine halted was used to create Surface Plot with polynomial trend-lines and the quadratic equation was applied to determine the optimal value for each type of thread, number of sewing layers, and thread-hole size. The values obtained were then set for another experiment, the results of which were that the sewing machine halted less frequently and the efficiencies thus increased about by 77.01%.