Every garment manufacturing unit deals with machine problems sooner or later—a thread that keeps snapping, a stitch that skips, a motor that runs hot. Most of these issues are common, predictable, and fixable without stopping production for long. This guide walks through the 10 problems we see most often on industrial sewing machines in Indian garment factories, what usually causes each one, and exactly how to fix it—plus which ones you should leave to a trained technician rather than attempting yourself. 
The 10 Problems, Causes & Fixes
1. Thread Breaking Frequently
Symptom: The top thread snaps repeatedly during stitching, forcing constant re-threading and stopping production.
Likely causes: Incorrect thread tension (too tight) • Old, bent, or wrong-size needle • Poor quality or old thread • Thread not routed correctly through guides
How to fix it: Rethread the machine fully, check the needle for burrs or bends and replace if needed, loosen the tension slightly and test on scrap fabric, and switch to a fresh spool of quality thread suited to the fabric weight.
2. Skipped Stitches
Symptom: The machine occasionally misses a stitch, leaving visible gaps in the seam.
Likely causes: Needle size doesn't match the thread or fabric • Needle and hook timing out of sync • Blunt or slightly bent needle • Incorrect needle insertion depth
How to fix it: Replace the needle with the correct size for your fabric and thread combination. If skipping continues after a fresh needle, the hook timing likely needs adjustment—this is usually a job for a trained technician.
3. Needle Breaking
Symptom: Needles snap during operation, sometimes more than once in a shift.
Likely causes: Needle bent from hitting a pin or seam allowance • Wrong needle type for the fabric (e.g. using a lightweight needle on heavy denim) • Operator pulling fabric instead of letting the feed dogs work • Loose needle clamp screw
How to fix it: Match the needle type and size to the fabric being sewn, tighten the needle clamp screw fully, and train operators to guide fabric gently rather than pulling it through.
4. Fabric Puckering
Symptom: The seam looks bunched or wavy instead of lying flat, especially on lightweight fabrics.
Likely causes: Thread tension set too tight • Feed dog height incorrect for the fabric • Wrong stitch length for the fabric type • Presser foot pressure too high
How to fix it: Reduce thread tension gradually while testing on scrap fabric; check that feed dog height suits the fabric weight; and adjust presser foot pressure—lighter fabrics generally need lower pressure and looser tension.
5. Thread Bunching Underneath (Bird's Nesting)
Symptom: A tangled mess of thread forms on the underside of the fabric near the bobbin area.
Likely causes: Bobbin threaded incorrectly • Top thread not properly seated in the tension discs • Bobbin case inserted the wrong way • Using a damaged or poorly wound bobbin
How to fix it: Remove and re-thread both the top thread and bobbin from scratch, following the machine's threading path exactly. Rewind the bobbin evenly and confirm the bobbin case is seated correctly before resuming.
6. Uneven Stitch Tension
Symptom: Some stitches look tight and pull the fabric, while others look loose—output isn't consistent.
Likely causes: Dirt, lint, or thread residue built up in the tension discs • Thread not seated evenly in the tension mechanism • Different thread types used on top and bobbin • Worn tension spring
How to fix it: Clean the tension discs thoroughly with a soft brush or compressed air, rethread carefully, and make sure the same thread type and quality is used on both top and bobbin. If tension stays inconsistent after cleaning, the tension spring may need replacing.
7. Motor Overheating
Symptom: The machine's motor feels hot to the touch or shuts off after extended continuous use.
Likely causes: Poor ventilation around the motor housing • Machine run continuously beyond its duty cycle without rest • Dust and lint buildup restricting airflow • Worn motor bearings
How to fix it: Clean dust and lint from around the motor regularly, ensure the machine has adequate airflow space, and build in short rest intervals during long production runs. If overheating persists even with proper ventilation, the motor bearings likely need professional inspection.
8. Noisy Operation or Vibration
Symptom: The machine runs louder than usual or vibrates noticeably during operation.
Likely causes: Loose screws or mounting bolts • Lack of regular oiling on moving parts • Worn belt or pulley • Machine not sitting level on its table
How to fix it: Check and tighten all visible screws and bolts, oil the machine per the manufacturer's maintenance schedule, and confirm the machine table is level. A worn belt or pulley showing visible wear should be replaced rather than run further.
9. Bobbin Thread Not Catching
Symptom: The machine sews, but no stitch forms—the bobbin thread isn't being picked up by the top thread.
Likely causes: Bobbin inserted backwards or upside down • Hook timing has drifted out of adjustment • Bobbin case not seated properly • Damaged hook or bobbin case
How to fix it: Re-check the bobbin orientation against the machine manual first—this fixes the issue more often than expected. If correctly inserted and the problem continues, the hook timing needs adjustment by a technician, since this involves precise mechanical calibration.
10. Machine Running Slow or at Inconsistent Speed
Symptom: The machine doesn't respond smoothly to the pedal—speed surges, lags, or stays inconsistent regardless of pedal pressure.
Likely causes: Servo motor fault or miscalibration • Foot pedal sensor wear or damage • Belt slipping due to wear or improper tension • Electrical connection issues
How to fix it: Check the belt for wear or slipping first, as this is the simplest fix. If the issue continues, the servo motor or pedal sensor likely needs professional diagnosis—these are precision electronic components that shouldn't be opened without proper training.
DIY Fix or Call a Technician?
Not every problem needs a service call, but a few genuinely do. As a rule of thumb: issues involving thread, tension, needles, and basic oiling are usually safe to fix yourself with the machine's manual on hand. Issues involving the motor, hook timing, servo calibration, or unusual noises are precision mechanical or electronic problems — attempting these without training can cause more damage and cost more to fix later.
Preventing These Problems Before They Start
Most of the issues on this list share the same root cause: skipped or delayed maintenance. A simple weekly routine — cleaning lint from the bobbin area, oiling moving parts per the manufacturer's schedule, checking needle condition, and keeping tension discs clean — prevents the majority of breakdowns before they happen. Factories running an Annual Maintenance Contract (AMC) typically see far fewer unplanned stoppages than those servicing machines only after something breaks.
When You Need Genuine Spare Parts or Expert Service
If a fix on this list needs a replacement part — a needle plate, bobbin case, hook assembly, or motor component — using genuine, brand-matched spare parts matters more than it might seem. Mismatched or duplicate parts are one of the most common causes of the same problem returning again within weeks.
Hari Chand Anand & Co. has been supplying and servicing industrial sewing machines across India since 1910, with genuine spare parts and on-site repair support for Duke, Hikari, Highlead, Kansai, and 20+ other brands. Our repair, AMC & spare parts services are built specifically for garment manufacturers who can't afford long production stoppages.
Facing a problem not fixed by the steps above? WhatsApp us directly or explore our services for expert diagnosis and genuine parts.