Industry Technologies
by Caleb Doty, Americas 21st, Inc.
Aging workforces, falling margins, and complex supply chains. The Sewing Industry is facing many headwinds as it finds its path forward, but there are opportunities ahead, and manufacturing is never going out of style. Still, it is likely there is no headwind quite as severe as the rapidly worsening shortage of Sewing Machine Mechanics, particularly in North America.
Ensuring Machine ReliabilityIndustrial sewing machines are complex pieces of equipment with numerous moving parts. Over time, wear and tear are inevitable. However, with proper maintenance and timely repairs, their lifespan can be significantly extended. Skilled sewing machine mechanics can diagnose and fix issues, preventing costly breakdowns and production delays. This much is obvious, but quantifying the effects can be complex. With investment capital typically moving towards exciting, high-margin industries, a factory’s inventory of sewing machines represents a massive investment and one that is poorly protected from the wear and tear of use and age. Mechanics are essential to securing that investment and using it to drive revenue, but as their numbers decline, the value of investing in equipment worsens.
Optimizing EfficiencyEfficiency is the backbone of any manufacturing process. As margins tighten, each point of efficiency you can achieve controls the impact of your bottom line. A narrow margin of efficiency separates the plants that thrive, and those that go out of business. Automation, process improvement, and workforce training are the key tools to pushing these numbers up, but each of these runs directly into the availability of mechanics. No automation delivers value if the machine doesn’t run, the most efficient process still needs working machines, and the most skilled operator still needs working tools.
Improving QualityQuality control is a non-negotiable aspect of textile manufacturing. Inconsistent stitches or other machine-related defects can result in subpar products. Once again, a rigorous quality program and investment in operator training can make the difference between you and your competition. Again, mechanics are necessary to maintain this. Countless machines with poor timing, awkward feeding positions, or improperly configured machines inject quality errors into the finished products, costing time and money to replace, repair, or answer unsatisfied customers.
Safety and ComplianceThe safety of the workforce is a top priority in any manufacturing facility. A well-maintained machine is less likely to pose safety hazards. In an era where finding and retaining a workforce is harder than ever before, unsafe conditions will ruin talent pools, skyrocketing insurance costs, and bury plants in lawsuits.
Adapting to TechnologyAs technology continues to advance, sewing machines are becoming more sophisticated. Mechanics must stay up-to-date with the latest innovations. Training ensures that mechanics can handle modern machines, including computerized systems and automation, allowing manufacturers to remain competitive in a rapidly evolving industry. Automation is widely trumpeted as the Panacea to the soft goods industries ills, yet it magnifies the shortage that is already the most crippling in the industry. Automated sewing equipment requires MORE knowledge and skill from mechanics than ever before. Not only mechanical skills, but the next generation must add programming, data management, AI tools, and much more to their skill sets.
Cost SavingsInvesting in training for sewing machine mechanics might seem like an added expense. Still, in the long run, it's a cost-effective strategy. Well-maintained machines last longer, require fewer repairs, and contribute to consistent, high-quality production. All of these factors ultimately lead to lower production costs, which leads to increased performance in both good times and bad.
A Matter of Survival
Each of the paragraphs above, taken individually, would still comprise a powerful argument for investing in the next generation of sewing machine mechanics. Taken together, it is an existential question. For the industry to survive, someone has to care for the equipment. Someone must form that bridge between the operator and machine, just to keep the manufacturer's doors open. Over the last three decades, the North American Industry has grown to rely on a single generation. The Generation that was young in the “Good old days” before offshoring, and before NAFTA. They learned their trade when Sewing plants spread across the US and Canada, employing thousands, and for decades, this generation of workers carried the responsibilities of keeping these machines running. They won’t do it for much longer. They want to retire and spend their twilight years in the peace and quiet they earned. But without them, the industry will not exist.
How do we do it?
There is no magic wand to wave here, this problem will take time, resources, and effort. My company, Americas 21st, has begun to move towards a solution, as have many others. Great people and organizations around the continent are starting to move towards a solution, but none of us hold the magic answer for everyone. Our contribution is a Fundamentals Course in Sewing Mechanic Training. Intended to give the next generation a strong foundation to build their career on. We run this course in our hometown of Greenville, SC, allegedly once a quarter, but usually much more often as the demand increases. There are other resources out there. ISAIC in Detroit, Michigan, works with Sewer Training, another critical operation. Sewing Machine manufacturers like Juki and Merrow have training programs to support their product lines. Dozens of community colleges and local governments are investing in saving their local industry. There isn’t one solution, there are a lot of parts to play here. But if you are reading this, and you care about this industry, I urge you to be part of this solution. There are many roles to fill. Contact: Caleb DotyAmericas 21st, Inc.339 Miller RoadMauldin, SC 29662(864) 297-3733
