Job Master Checklist for Embroidery
Purpose: Quality Control tool.
Master List File Name: SPECFRME
Format: Two to a Page, 1 Part
According to Scott Ritter, the most frequent question he is
asked in seminars or by clients is "How do I reduce errors in the shop?"
Obviously, the answer is to have a well run, established, and integral quality control
system. That does not have to be a tough task to implement. This form was created to serve
as the main quality control tool for most shops. This system works great for any size shop
from a one-man (or woman) operation to enormous multi-location companies. Even though the
form was created with multi-employee handling in mind, one-person shops find that
completing each phase of the checklist helps insure accuracy.
Use: The concept is simple. Initially, the
work order for each job issued into production is placed on a clipboard along with one of
these checklist forms. At issuance, the header box is filled out, denoting the customer
name or account number, the job number and the order date. These items should correspond
with the same information on the work order or order form (if a similar field exists)
First stop is digitizing. If the design needs a new tape or
disk created, the digitizer will fill out all the particulars for this design as he
creates it. If stock lettering or designs are all that is needed, the person
responsible for arranging the design will fill this portion of the form. The form has an
area where somebody must initial that the customer has approved the
design, and those initials must be on the form before the digitizing department head
will sign the section as complete. The order does not go into production until the
digitizing department has "signed off" on it's part of the form.
The next step is the embroidery setup section. People
completing work on this order must initial or sign as the goods are picked for the order,
and as the machine is set up. At each step, the person completing the work should have
another individual "co-sign" that the work has been performed correctly. When
the operator has the machine ready to go, a second individual co-signs that the thread
colors are correct, and that the machine will use them in the correct order. At that
point, the operator performs the first run, and then another person inspects the first
run, verifying that the design, the colors, and the locations match the work order.
Only then does the operator proceed with the rest of the batch.
After the order is sewn, the packager recounts the order to
make certain the correct quantities are being shipped, and checks the garments for
defective work. When satisfied, the packager / inspector signs the checklist. He or she
also denotes whether any items found defective were replaced with new, so that the
shipment is complete per the order, or if the shipment is short (or over) so that the
bookkeeping department will be alerted to check the order for billing quantities. When the
order is packed into boxes, the packager initials the area denoting this action. Then, the
people who enclose the packing list initial their space, and the shippers initial and date
the shipment.
When the order is completed, the checklist is stapled to the
work order, and filed away for future reference. This way, if a concern should arise about
the quality of an order, the individual responsible for each phase becomes accountable.
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