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Internet of Things and Maintenance Management

Single Needle Direct Drive Lock Stitcher with DigiFlex Electronic
Feeding System and Thread Trimmer

By
Pratik Raj
BFT/17/548

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Acknowledgement
In the accomplishment of this document successfully, many people have best
owned upon me their blessings and the heart pledged support, this time I am
utilizing to thank all the people who have been concerned with the completion of
this document.
Firstly I would like to pay my sincere thanks to our subject faculty Mr. Neeraj Kumar
and Ms. Nilima Regina Topno for providing us with the opportunity and guidance to
complete this document.
I would also like to convey my deepest gratitude to my family and friends who also
helped us to complete this document.

Pratik Raj

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Certificate

This is to certify that I, Pratik Raj student of Bachelors of Fashion Technology,

Semester V from National Institute of Fashion Technology Patna has completed
this project under the able guidance of their subject faculty Mr. Neeraj Kumar &
Ms. Nilima Regina Topno. It is authentic work and has not been copied from
anywhere.

( ) Mr. Neeraj Kumar

( ) Ms. Nilima Regina Topno

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Single Needle Direct Drive Lock Stitcher with DigiFlex Electronic Feeding
System and Thread Trimmer

Figure 1 Brother S-7300

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Brother Continues to Drive a New Era of Product Excellence and Industry

Change
Since its interception in 1908, Brother has been at the forefront of product
innovation, dedicated to delivering superior and innovative sewing technology to
their customers.
It is with this spirit that they introduce a new line of NEXIO industrial sewing
machines. This new line of NEXIO is for IoT era of industrial sewing machines with
network connectivity that will set a new design standard in the industry.
This new brand is derived from the words “Next” and “Society”.

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IOT compatibility
Enables low cost
operation with
flexible system
where the real-time
production can be
controlled

DigiFlex system can Enables to observe

resolve the issue of the working ratio of
oil stains in the each sewing machine
garment due to the theat helps find the
adoption of the
sealed oil pan
Why it is low working
efficiency point

needed in
your
Industry?

Graphical displays
also enables a
Enable to keep the comparison of the
track of production output from multiple
status sewing machine
leading to better line
balancing

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Specifications

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Features

 World‘s first DigiFlex Feed Control directly connected with a stepping motor

DESCRIPTION: The feed motion can be changed with one touch of a button to
provide best sewing quality for various materials. Furthermore, the sewing stitch
length can be digitalized, stabling the stitches.

 Equipped with colour LCD touch panel for intuitive operation

DESCRIPTION: Display items with illustration icons, offering user-intuitive operation.

For panel display, Easy mode Home (for operators) and Detailed mode Home (for
mechanics) are available. Each mode is highlighting the necessary and useful
functions according to the users so they can grasp the needed information at a
glance.

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 Reduction of disposition of thread ends

DESCRIPTION: The new hook which is improved the thread cast off enables to
expand sewing range for medium materials. Thread left-over is reduced to 3 mm
from 5 to 6 mm.

 Offers a new value with Design Stitch

DESCRIPTION: We can change the stitch length on the same seam by program control.

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 USB Port

DESCRIPTION: The USB port is equipped so sewing patterns and environmental

settings can be copied easily to other sewing machines. Also, we can upgrade the
software with USB memory.

 The compensation stitch with a half-length stitch available for better corner sewing

DESCRIPTION: We can use both Switch A and B each for compensation stitch and
half-pitch compensation stitch as sewing portion.
When sewing the corner of jeans, for example, we can use half- pitch in order to
align the stitch on the corner.
S-7300A reduces operator’s work load by changing the manual operation to be digitalized.

S-7300 A garnered a huge response from the visitors because of its various
solutions offering to them. The main highlights are:
o Productivity Improvement

i. S-7300 is IOT compatible which enables low cost operation with flexible
system where the real-time production can be controlled from anywhere.
The production data can be visualized in the form of a bar chart that enable
to keep the track of production status. Graphical displays also enables a
comparison of the output from multiple sewing machine leading to better
line balancing and helps to find a bottleneck. Also, it further enables to
observe the working ratio of each sewing machine that helps find the low
working efficiency point.

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ii. The machine features a DigiFlex Feed (DFF) system that can resolve the issue
of oil stains in the garment due to the adoption of the sealed oil pan and also
the minimum lubrication system prevents problem such as oil leakage and
oil scattering drastically.

iii. Less needle breakage means better productivity. Through the introduction of
Digiflex feed the productivity is improved by 50 % reducing the rejection rate
to 40 to 50 %.

1.6

1.4

1.2

0.8

0.6

0.4

0.2

0
Conventional Feed Digiflex Feed

Productivity Improvement

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o Quality Improvement

High quality of sewing on any product is achieved through the installed digiflex feed

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Feed System Feed Motion Image Description

Standard oval Most common

feed mechanical feed
motion

Digiflex feed Improved thread

Front rise feed tightening/ prevent
ply slippage

Digiflex feed Fewer needle

Back rise feed breakages Reduced
thread
tightening/puckerin
g

Digiflex feed Improved feeding

Rectangular feed Fewer needle breakages
than
front rise feed
Effective for cross-
over seam/heavy
materials

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o Operating ratio improvement

A simple, single button step up helps in 14 % improvement than conventional feed .

175

170

165

160

155

150

145

140
Conventional feed Digiflex feed

Operating Ratio

Result

Figure 3 Puckering Reduction on run stitch of Figure 2 Roping reduction on bottom

light materials hemming

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Installation

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In a nutshell, this technology can visualise the workplace and we can check project
process by comparing our current and target production status. It can fulfil many
requirements and dramatic increase in productivity by earning profit. Iot
compatibility in this technology is like a cherry on the top that is the new trend and
the face for Industry 4.0.

Sewing Maintenance Checklist

Many Retail, Brand-name Marketing, Mail Order and Sourcing Companies are
visiting existing and potential Contractor sewing facilities and evaluating their
sewing capabilities for producing quality products for their customers. In many
cases they even rate the vendor and give the plant a grade based on their
observations during their visit. Generally one area that is evaluated is the sewing
floor and the condition of the sewing equipment. Before we look at the Checklist
on the following pages, let us look at the many factors affected by poor sewability
and they include:
• Seam Quality

• Seam Appearance

• Seam Durability

• Sewing Operator Productivity & Earnings

• Sewing Operator Morale

• Manufacturing Through-put time

• Products produced may require greater inspection

• Higher costs and lower profits

• Consumer dissatisfaction

• Loss of Brand-name credibility

The following checklist was developed to help you evaluate sewing processes in
order to optimize sewing and seam performance.
Preventive Maintenance-

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 Check to see if the machines are being kept clean

 Machines should be blown off every day to remove lint and trash

 On lockstitch machines, the hook should be blown off regularly during the day to
prevent lint or dirt from building up in the oil ports in the race of the hook.
 Check to see that the machines are being lubricated regularly.

 Oil levels should be checked daily and additional oil added if necessary.

 Randomly check the oil levels in the machines.

Stitch forming system

 The sewing machine needle should be inspected regularly during the day
and replaced if there are signs of wear or damage.
 The correct type & size of needle should be used.
 The correct needle size - thread size relationship should be maintained.
 Lockstitch machines-
 Check the hook for sharp surfaces and burrs on the hook point.
 Check for other sharp surfaces on other thread contact surfaces.
 Check for excessive wear in the raceway which will allow excessive movement in the
basket
Thread Handling System
 Check to make sure thread is being stored properly.
 Cones should stored properly to insure that they are not contaminated with
dirt, excessive lint, etc.
 Check to make sure wind on part cones does not affect take-off the cone.
 Check to make sure the correct thread type and sizes are being used.
 If thread vendor is specified, check order book and inventory to make sure
the proper thread is being used.
 Thread stands are in proper condition and the top eyelets are oriented properly.
 Optimum distance between the top of cone & top eyelet (should be no more
than one cone higher than cone size being used).
 Thread stand eyelets are smooth and not grooved or damaged ‰Cone is
held in a vertical stationary position.
 Machine eyelets and guides are smooth and not grooved, rusted or damaged.

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 Machine thread tensions are as light as possible but still give balanced stitches.
 Observe how much of the tension post is exposed beyond the tension nut.
 Generally the more of the tension post that is visible, the more tension that
is being applied to the sewing thread.
 Observe the condition of the tension discs, take-up spring, etc.
 Check the bottom tension to make sure it is as loose as possible and still give a
balance stitch
 Lockstitch machines
 Bobbin winder in good condition & making correct wind on bobbins
 Condition of bobbins & bobbin tension
 Look for nicks on edge of bobbins indicating incorrect needle height
 Look for damaged or bent bobbins
 Check bobbin tension (minimum tension recommended)
 Bobbin tension of bobbin case
 Bobbin tension with bobbin case laying on a flat surface
 Bobbin tension after bobbin thread has been pulled up through the hole in the
needle plate
 Needle thread
 Machines are properly threaded
 Needle thread tension is as light as possible but still give a balanced stitch
 Take-up spring in proper positioned and working properly
 Proper thread size / needle size relationship is being maintained
 Proper needle thread size / bobbin thread size is being used

Feed System
 Needle Plates are in good condition
 Make sure the needle hole size /needle size relationship is correct
 Generally the needle hole size should be twice the diameter of the needle being used
 Check to make sure the needle hole in the needle plate is not damaged
 Look for needle damage and sharp edges
 Check to see if the needle plate is flat and not bent down at the needle hole
 Feed Dogs are in good condition and correct for the application
 Check to make sure the feed are not broken or damaged
 Observe the teeth per inch on the feed dog

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 Overedge Needle Plates

 Check for needle damage or burrs on the needle hole and stitch tongue
 Make sure the trimming knives are adjusted to the width of the needle plate stitch
tongue
 Presser Foot-Correct foot is being used for the application
 Make sure the needle hole size/needle size relation is correct & the needle has
sufficient clearance
 Check to make sure the needle hole is not damaged
 Check for proper pressure both in front and in back of the needle
 With the foot flat on the needle plate, you should not be able to insert a thin
piece of paper between the foot and the needle plate from the front or back
side of the needle
 Check presser foot for excessive wear causing side-to-side play
 The pressure on the Presser Foot should be as light as possible and give a uniform
stitch length
 Check to make sure the correct stitch length is being used

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Bibliography

 https://www.brother-ism.com › products › industrial-sewing-machines

 https://industrialsewingmachine.global.brother/en-ap/lock/s7250a/feature/index.aspx

 https://industrialsewingmachine.global.brother/en-ap/lock/s7250a/feature/index.aspx

 https://tzeko.gr/en/product/s-7300a-nexio/

 https://aces.nmsu.edu/pubs/_c/C102/welcome.html

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