High-production embroidery staging is partly a matter of organizing the production floor in the most efficient manner possible in terms of workflow, then making certain everything needed by each machine operator is close at hand.

Staging embroidery production has to rank as one of the more important considerations for a high-volume promotional-embellishing environment. Staging includes a of elements in the process, and may be thought of as the embroidery process loop. Everything involved, from supplies and table locations, to floor plan and shop layout, to receiving, finishing and shipping locations, influence staging and, ultimately, production efficiency.

Let us first define “high volume” and how it applies to us. Huge operations with hundreds of embroidery heads are fast become a dying breed here in the states. Much of that type of volume has found its way overseas to industrial factories often with thousands of heads. Today, we might define a domestic high-volume operation as 24 to 30 heads, or sometimes more. However, there are plenty of four- to six-head operations employing the strategies outlined below to maximize productivity.

Also, let’s take a look at why we might wish to become more heavily involved with needles and thread. With margins shrinking and competition increasing, one must expand one’s portfolio. It is written that a smart man sews many crops. More likely in our industry, it becomes obvious that many customers needing screen-printed apparel will also need embroidered apparel, heat-transfer products, digitally applied graphics, promotional items, trophies and more. Adding or increasing embroidery production means adding or increasing a revenue source and, if your level in the marketplace involves high volume in any discipline, it is essential high-volume thinking be applied to all disciplines.

Thankfully, we have been able to adapt strengths from the screen-printing portion of our experience to other areas. Our business is about providing a quality product at a competitive price, on time. Sounds simple, and it is, in concept. Execution, however, is a bit more difficult. I can’t see much difference between screen printing and embroidery in that regard, except for the fact that embroidery production—per-piece—is a lot slower than that to which screen printers are accustomed. Our automatic screen-printing presses can run at over a thousand pieces per hour. Compare that to four hoop changes per hour for an average left-chest logo. Those same thousand screen-printed pieces can take a full 24-hour period for 12 heads of embroidery. While it is sometimes easy to get caught up by the artistic side of digitizing and embroidery, if we don’t pay equal attention to productivity and the processes involved, we can get into big trouble. As business owners, profit must be a major consideration. Excellent productivity will only increase profit.

General workflow

To create an efficient workflow within the embroidery work area, each part of the process needs its own space. The physical workflow starts in receiving, then moves into a staging area where the raw product is prepped. From there it is hooped, embellished and finished, including trimming, cutting out backing, topping removal and, finally, steaming out hoop marks. The garments are then packed and made ready for pick-up or shipping. A clearly delineated route along this path is necessary for a clean flow of work. Each work area has specific tools that are applicable only to the procedures of its part of the production loop. Enough space is needed to have all supplies to an applicable work station stored in its area. Thread, bobbin and backing inventories should be stored close to the embroidery equipment for obvious reasons.

Production embroidery machines are available from single-head to 30-head. Determining the right equipment and its proper layout is critical. Starting with a general understanding of production needs, flexibility and technology should be significant factors in determining the type of machines installed.

We prefer to positioned embroidery equipment in a linear fashion with an eye toward efficient movement of product. When setting up new installations, we position machines aligned with an appreciation of the production loop relying on logic to determine the layout. Multiple, smaller embroidery machines—in four- to six-head units and even several single-heads employing one operating system—can be configured in horseshoe or U-shaped footprints.

With the really large orders heading off shore, the flexibility and efficiency of smaller machines gives us more options and versatility than with those larger than 12-heads. Finally, the layout of the workspace often depends on the floor space actually available, and the physical dimensions with which we have to work.

As production-embroidery machines are available in widely divergent sizes and configurations, determining the right equipment and its proper layout is critical. Starting with a general understanding of production needs, flexibility and technology should be significant factors in determining the type of machines installed.

Supporting players

An effective method of overall staging and production flow is to remove final inspection and finishing, trimming and removal of backing to another location within the plant. The embroidery operators do not handle this portion of the process, as they must be focused specifically on keeping their machines running efficiently.

As the only thing we can do little about is machine running time, we concentrate on keeping them running, avoiding downtime whenever possible. With this in mind, we double up on our hoops and automate the hooping process as much as possible using hooping machines, lasers and hooping stations. No embroidery machine should ever be waiting to be unloaded and rehooped. Just as with screen printing, minimizing downtime adds to the bottom line. We don’t make money burning screens or hooping garments; we make money while the machines are running. Well trained, highly motivated employees—including hoopers, operators, trimmers and steamers—are extremely valuable. Integrating a team atmosphere is also huge. We are still only as strong as our weakest link, and our people are the most important piece of the puzzle.

Additionally, we always want to have the next several jobs ready to be loaded up on the embroidery machine for which it is scheduled. Quick change-over is critical to reduced downtime. Thus, staging should be complete with product unboxed and laid out on tables or racks with the garment panel on which the embroidery is to be placed facing up. Digitizing, approved sample, paperwork and any thread changes should be located with the garments.

Thread changes can be made on needles not running, while final images of the previous job are finishing. Staging similar products with similar sewing requirements is highly advised for obvious reasons. Different products and fabrics require different needles and/or backing.

Likewise, flats versus caps require major machine alterations. If we can avoid major changes to machine set-up, we can keep feeding it without interruption. At least two sets of hoops are required, and at minimum a second set of garments is always staged and ready to replace the garments sewing on the machine.

Hoop changes should be very quick. Once loaded and sewing, the previous hoops are removed and new garments hooped for the next change-over. Again, finishing is moved to another department for trimming, backing and topping removal, steaming, folding, bagging and boxing. A careful final inspection and quality assurance is emphasized in this department, without compromising the unbroken rhythm of production.

Cleanliness is next. . . .

Because they represent an expense, some shops consider extra hoops and cap frames to be a luxury. If, however, their lack causes a machine to sit idle for even a minute longer than necessary, not having them is wasting you money.

If you are like me, you’re still trying to figure out what you want to be when you grow up. Working smarter not harder may be an over-worked cliché but, again, it applies. Keeping a clean operation not only minimizes waste but also shows the customer what type of plant you are running. A clean, tidy and well organized workspace goes a long way toward a first impression on new customers, to say nothing of its effect on staff morale and efficient production flow.

We run our embroidery heads and set-up operations world wide, right next to automatic presses in the screen-printing department with minimal division and climate control. Here in Colorado, where humidity is nearly a non-issue, we have made some accommodations such as using roll-on adhesives rather than aerosols, which is excellent for the embroidery environment.

We are impeccable with regards to keeping all the machines clean and well maintained, and haven’t run into any major problems . . . knock on wood. Maintenance becomes minimal with efficient organization, but following manufacturers’ recommendations is very important. Keeping of spare parts is important as well.

Staging is paramount in maximizing productivity and efficient use of time, minimizing mistakes and eliminating unnecessary steps in handling. Excellent staging practices are essential and will increase profits by reducing labor, minimizing scrap rates and creating an efficient workflow environment.

That’s right: working smarter not harder. Having an efficient, well-organized embroidery operation makes the entire staff feel and act more productive, raises moral and raised the bottom line. This is how we run our plant and set up others as well, and it turns out the processes of embroidery and screen print can be very similar from the beginning to the end. Two different decorating methods but, when it comes to staging, one process.