In the apparel industry, seam performance is one of the essential quality standards, directly affecting product appearance and customer satisfaction. The seam performance will be affected by many factors, from input material specifications to machine parameters combined with the skill level of the workers. This study applied general factorial design to investigate the impact of fabric thickness and presser foot pressure on seam puckering, one of the most significant quality standards in seam performance in single jersey fabrics. The results revealed a significant impact of fabric thickness and presser foot pressure on seam puckering (p < 0.05), with thinner fabrics and lower presser foot pressures associated with increased puckering. A significant interaction between these factors was determined, highlighting their combined influence. The developed regression model effectively predicts seam length variation, explaining a substantial portion of the variability (R-sq = 89.33%), making it an invaluable resource for optimizing sewing parameters to mitigate seam puckering. This research highlights that by reducing defects and improving process control, the findings help move towards more sustainable textile and garment production, which cuts down on material waste and makes better use of resources for lasting environmental and economic advantages important for sustainable development.