This paper aims to provide rapid and precise methods to allow industrials to predict the amount of sewing thread needed to sew a garment using different lockstitches of class 300 (301, 301/301, 304, 308, 309, 310, 311, 312, and 315). To avoid unused stocks for each stitch type, a sewing consumption value was determined using a geometrical method of different lockstitch shapes. Furthermore, the relationships between overall geometrical models of the studied lockstitches of class 300 were developed. Indeed, based on the geometrical model of lockstitch type 301, all theoretical models proposed were investigated and proved to be accurate. Moreover, referring to the findings, the prediction of the sewing thread consumption relative to each investigated lockstitch was proposed as a function of the studied input parameters. To improve the established models using geometrical technique, a statistical method was conducted. In addition, based on multi-linear regression, compared geometrical and statistical results were discussed and the coefficient R2 value was determined to evaluate the accuracy of the tested methods. By comparing the estimated thread consumption with the experimental ones, we concluded that the accuracy of the models is significant (R2 ranged from 93.91% to 99.10%), which encourages industrialists to use geometrical models to predict thread consumption. Therefore, the accuracy of prediction using the geometrical method is more accurate than the statistical method regarding the range of R2 (from 92.84% to 97.87%). To classify the significance of all studied parameters, their contributions to the sewing thread consumption behavior were analyzed in the experimental design of interest. It was concluded that the most important parameters affecting thread consumption are stitch width, stitch density, and the gap between two needles. The thickness of fabric has a low contribution to the thread consumption value, whereas the effect of yarn count can be neglected.
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