Technology Technology that creates excellence for sewing machines

Sewing factories support the glamorous apparel industry behind the scenes. Lots of industrial sewing machines are laid out there, and the operators move their hands and fingers devotedly.
Looking in the direction, you can see sewing machine needles moving at a blinding speed, from 7,000 to 10,000 rpm. This speed is far beyond that of home sewing machines.

Car engines usually run at a speed of less than 3,000 rpm. Industrial sewing machines in a sewing factory are employed for more than 10 hours a day, and more performance, precision and durability are required for industrial sewing machines, compared to cars.
ndustrial sewing machines do not often come under the spotlight. However, they are essential in sewing factories that produce clothes worn by people in the world.
PEGASUS produces industrial sewing machines that keep running everywhere around the globe!

High quality and durability that support sewing factories all over the world

Mr. Mukai of the R&D Department said:
Using a PEGASUS sewing machines, there are no motor seizures and/or oil leakage problems even while industrial sewing machines are running at such high speed, in different and tough environments in various locations around the globe. That' s great, isn't it?

PEGASUS' industrial sewing machines can run at 7,000 to 10,000 rpm continuously, in various usage environments varying in temperature and humidity.
Iron parts chafe with each other repeatedly inside the machine. In order to prevent damage to these parts due to abrasion, oil is employed as a lubricant. If oil leakage occurs, it will cause rejected products. Therefore, durability is more demanding for industrial sewing machines than most people think.

Following Mr. Mukai, a younger staff member, Mr. Kuhara said:
PEGASUS has a long history of excellence in durability, way back in 1964 we passed the international durability test, which was sponsored by Courtaulds PLC. in England. In fact, PEGASUS was the only winner of that contest. Accordingly, PEGASUS was recognized as a top brand in the industrial sewing machine and apparel industries. Since then, as a company tradition, PEGASUS has focused on durability tests.
Durability tests are always conducted in a space where strict standards are set regarding temperature and humidity. Parts that employ rubber or resin, especially parts that tend to deteriorate, should also pass these tests comletely.

PEGASUS' unique measures against oil leakage, which is the most important problem in the whole industrial sewing industry, have caused a stir in the industry. We developed a part called an oil seal that prevents oil leakage effectively. It was thought that it was difficult to attach an oil seal to a high-speed machine. However, PEGASUS developed its own unique oil seal. Our oil seal has a design that is partially changeable. This feature received a high evaluation in the market.

The prime requirement is assembly technique with micron accuracy.

An industrial sewing machine includes a main part frame and more than 500 separate parts. In other words, you have to go through more than 500 procedures, in order to completely assemble only one machine. Therefore, even a one micron misalignment during the assembly process reduces the accuracy of the whole machine.

Especially, the main shaft that is called the heart of an industrial sewing machine, which changes the motor rotation to the needle up-and-down motion, is never permitted to have even a one micron misalignment. This main shaft has a lot of divisions and holes with different diameters. These multilayered holes are totally aligned with great accuracy from end to end. This accuracy goes far beyond cold word, such as machine accuracy or precision, achieving a form of artistic beauty.

Mr. Muraosa of the Manufacturing Technology Department said confidently:
PEGASUS never outsources the manufacturing of the main shaft and the body frame. We have been manufacturing the hearts of our industrial sewing machines by ourselves since the day the company established, while other industrial sewing machine manufacturers are forced to use outsource manufacturers. This is possible only because we have our own processing technology that can control accuracy at the micron level.
Therefore, PEGASUS has firmly established its position as a world leading brand.

Power of production technology that supports small-lot production of a diverse product mix

Why does PEGASUS stick to in-house manufacturing?
Mr. Muraosa answered:
We employ in-house manufacturing because we may gradually lose track of manufacturing if we employ outsource manufacturers. Therefore, we usually keep our technology in our house. If defective products are produced, we will be able to know why, where and how they have been produced, and determine easily how the manufacturing method should be modified and improved. In addition, we will be able to provide advice to overseas factories earlier.
This system is absolutely related to the quality of our products.
PEGASUS employs a special machine exclusively for manufacturing the body frame, and we usually maintain this machine by ourselves.

The industrial sewing machine world has several additional deep aspects. The operators in the sewing factory each has his/her assignments, which they conduct one by one.
The sewing machines used for sewing sleeve openings and those for joining shoulders are different. Therefore, PEGASUS produces approximately 3,500 different sewing machines. In order to respond to small-lot production of a diverse product mix while maintaining a high level of accuracy, the capabilities of production technology and assembly efficiency become major factors.

In addition to the comments above, Mr. Muraosa said:
PEGASUS also designs jigs, one of the aids employed within the company. Designing these jigs demands a higher level of accuracy than designing industrial sewing machines. In fact, we always feel the weight of developing continuously-accumulated technology that can respond to the higher level of accuracy the market requires. Everyday, efforts are accumulated continuously.

Spreading the inspection standards for tens of thousands of PEASUS' parts out to the overseas bases

PEGASUS has a person who can never be taken off the jobs when we talk about jigs.
He produces the inspection standards for PEGASUS' parts all by himself. He stays abroad a third part of each year, in order to spread these inspection standards out to the overseas bases. The person in charge of PEGASUS quality assurance is Mr. Muramoto.

Mr. Muramoto said:
If the accuracy of each part is not ensured separately, correct assembly will not be secured. Parts with a high level of accuracy determine the quality of finished machines.

PEGASUS has sharp eyes pursuing a high level of accuracy.

Everybody should inspect parts correctly and uniformly. Mr. Muramoto designs initial inspection methods for quality checking, and creates inspection standards. Basically, the parts manufacturer has already inspected each part. Therefore, the parts should be up to the standards. On the top of those tests, the Muramoto's tests will be the final barrier, in order to obtain PEGASUS higher quality. Reaching this goal requires the development of jigs for inspection. In addition, a higher level of accuracy is also inevitable for these jigs.

Mr. Muramoto is now planning to implement these strict inspection standards in the overseas bases. If the local staff members control these standards on the spot and with the same level as his, there will be no need for him to go abroad, and the high level of accuracy and efficiency will be ensured in overseas bases. His endless hard work and efforts support the quality control field.

Advancing PEGASUS' production and processing technologies fostered in the industrial sewing machine industry to the field of manufacturing die casting parts

PEGASUS' high-precision processing technology was fostered in the industrial sewing machine industry.
This technology also makes a strong showing in the production operation for die casting parts. The die casting industry is more competitive than the industrial sewing machine industry. This is why the automobile industry always strictly pursues quality control. We should supply lots of die casting parts while competing with the world's auto parts manufacturers, in order to meet customers' requirements. In addition, we should expand the market throughout the world.

Mr. Koh, the representative of PEGASUS (TIANJIN) SEWING MACHINE CO., LTD. and Mr. Haraguchi, the representative of PEGASUS SEWING MACHINES CO., LTD. in Vietnam said vigorously:
In order to survive in this industry, which demands overwhelmingly strict quality control, an incredible capability of quality control and price competitiveness are essential. In other words, we must fight this battle everyday all year long.

Mr. Koh and Mr. Hraguchi said:
We do not perform a burring operation, but rather a processing operation. This idea is one of our strong points. Employing PEGASUS' technology accumulated for 100 years has provided us with a major advantage in this new field.

PEGASUS never outsources manufacturing of the body frame, but sticks to in-house manufacturing with accuracy at the micro level.
This concept has been effective in the new field. PEGASUS' processing technology for small-lot production of a diverse product mix has been proudly competing with mass production in the automobile industry.
Our manufacturing spirit, which PEGASUS has been building up step by step as a leading manufacturing company exclusively for industrial chainstitching (Kan-nui) machines.
The basic concepts never change. Therefore, we can produce excellent products in the different industry.