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“If you are manufacturing lifting slings or cargo lashings, the move to RSG’s automated systems isn’t just about speed—it’s about global competitiveness. By utilizing RSG’s patented thread monitoring, you eliminate ‘fake seams,’ ensuring 100% quality repeatability and avoiding costly recalls. The ROI is immediate: our automatic bobbin exchangers allow for continuous production without operator intervention.
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1. How
   can I ensure seam consistency in 4-ply polyester lifting slings?
   RSG’s automated sewing process employs a cnc-driven sewing process. Pre-programmed sewing patterns can be chosen / SKU
2. What
   is the maximum sewing thickness for heavy-duty cargo straps
   The general answer is: RSG can choose from various sewing machine manufacturers. 1/4″ is doable, thicker needs to be tested.
3. How do
   I prevent “fake seams” in safety-critical lashings?
   RSG-automation has a patented sewing thread monitoring system. If the bobbin (in the chain-stitch machine) runs out of thread, the machine will stop prior to depleting it. It can be connected to an automatic bobbin exchanger, which can replace up to 8 bobbins from a pre-loaded cassette. The to thread is monitored, as well.
4. What
   is the production speed (parts per minute) for automated sling sewing?
   The machine’s “bottleneck” is almost always the sewing. And the sewing portion depends on the amount of stitches needed to complete the sewing. A rule of thump is that the machine replaces the workload of 3-5 people in general.
5. Can
   one machine sew multiple narrow webbing slings simultaneously?
   The short answer is yes, but in most cases, such a solution is cost prohibitive.
6. How
   does an automatic bobbin changer impact machine downtime?
   The automatic bobbin exchanger ensure a continuous product run. The customer needs to have a bobbin-winding machine, made by RSG. This will be compatible with the bobbin exchanger. 8 bobbins can be charged automatically. In this conjunction, it is worth noting that the operator of a fully automated sewing machine from RSG utilizes only approximately 25% of his/her time. 75% of the remaining time can be utilized for completely other task, not directly relevant to the machine itself. E.g. packaging or boxing of materials.
7. What Poka-Yoke and how is it implemented?
   Poka-yoke is a Japanese lean manufacturing technique meaning “mistake-proofing” or “fail-safing” that uses simple, often inexpensive devices to prevent errors before they occur or make them immediately obvious. Developed by Shigeo Shingo, it aims for 100% quality by detecting defects at their source, rather than via inspection.
   RSG has a patented, bobbin monitoring system, based on a color combination. The machine recognized when it runs out of sewing thread in the bobbin and will initiate an automatic bobbin exchange, to ensure a continuous production run.
8. What
   is the advantage of a hot blade cutter?
   The hot blade cutter in RSG – automated sewing is a patented way of cutting e.g. nylon tapes or webbings. it cuts, but also seals the end. No fraying occurs, which reduces additional needs for finishing the cut tape.
9. RSG-fully automated sewing machines are yielded for high-volume outputs. What if I do not have that volume to justify such an investment, yet?
   In standard applications, the fully automated sewing machine
   a) lengthens the tape/ webbing, then
   b) adds hardware and sews the buckle in, then
   c) packages & discards the finished item
   Basically, these three steps can be handled as stand-alone units, or two units could be combined.
   This may be helpful in following scenarios:
   a) If the demands for lengthening largely exceed the need for sewing
   b) If there are too many different SKUs which cannot be grouped within the machine’s acceptable tolerances and therefore reduce the SKU by volume to a too low point.
   d) There may be the demand for two machines pertaining sewing, but only one pertaining to lengthening.
   That said….RSG also offers hybrid versions. In that case, an operator would load up a template with multiple SKUs and feeds it into a the sewing machine. While the sewing machine does its work, the operator loads the next template. This is seen especially when processing heavy duty straps.
10. How complicated is the maintenance?
    Actually, the machines are built for 24/7 runs and hardly require any maintenance. Sealed bearings and enclosed components eliminate the need for maintenance. Any potential “care-giving” requirements are self-explanatory and can be handled by a person with mechanical understanding.
    In addition, the machine could be equipped with an internet connection, allowing to remotely analyze the machine on demand.
11. How do
    I integrate automated sewing into an existing narrow fabric line?
    I think in above 98%, this is not feasible for following reasons:
    a) The narrow tape knitting equipment would need to be able to keep up with the sewing line. While this may be redundant for low cost solutions, a fully automated sewing line from RSG processes more than one single knitting machine could handle.
    b) The product does not have to be processed from a roll with a limited length. The tape can be spliced with e.g. an aluminum tape. The machine recognized this spot, cuts it out and continues the production without downtime.
    Splices are typically made when working out of a big cardboard box (Gaylords). If both, the beginning and ending end are sticking out of the box, splicing can be done hassle free.
12. Does
    automation help in meeting international safety standards (ISO/EN)?
    Absolutely, the machine can monitor data which can be provided later for analytical purposes and proof of quality control.

• This reply was modified 5 months, 3 weeks ago by  TEXBOOKHOST.

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